Moisture-resistant / oil-resistant composite material

Abstract

Oil and water resistant compositions and methods of making and using such compositions are described. The composition can be used to make oil and water resistant articles. The oil and water resistant composition may include fibers, a polysaccharide, an acid, and water; wherein the composition is water and oil resistant upon compression and heating. Other oil and water resistant compositions may include fibers, blockers such as fatty acids, metal salts of fatty acids, or combinations thereof, and water, wherein the compositions are water and oil resistant when compressed and heated.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. application No. 17 / 880,219, filed on August 3, 2022, the contents of which are hereby incorporated in their entirety. Background Art

[0003] Disposable plastic packaging made of petroleum-derived polymers such as polystyrene, polypropylene and polyethylene has become a problem due to littering, persistence in the environment, difficulty in recycling, reduction of fossil resources, and animal ingestion and accumulation in the body. In contrast, cellulose-based food packaging has become increasingly popular due to its biodegradability, compostability and sustainable production with plants as raw materials. Examples of cellulose fiber food containers include cups, plates, flip-top boxes, paper packaging, etc. However, there is a problem that oils and greases in food can penetrate into such containers and transfer to hands, clothes and desktops. Therefore, these products are usually coated with materials that prevent water and oil absorption, such as polyethylene, petroleum wax, acrylic acid, poly (ethylene-co-vinyl alcohol), polyvinylidene chloride or polyfluoroalkyl substances (PFAS). These materials are all non-biodegradable, and the adhesion of these polymers to paper substrates makes it difficult to recycle. In particular, PFAS may cause cancer and other chronic health conditions. Starch coatings are effective grease barriers, but are usually easily damaged or dissolved in cold or hot water, which reduces their barrier properties.

[0004] Therefore, there is a need to make hot water and oil resistant uncoated composite sheets that do not use fluorinated compounds and are biodegradable or compostable. The compositions and methods disclosed herein address these and other needs. Summary of the invention

[0005] Provided herein is a fibrous matrix comprising pulping fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof. In some embodiments, the fibrous matrix may further comprise an internal sizing agent, such as an alkyl ketene dimer; a filler, or any combination thereof.

[0006] The present invention also provides a fiber matrix, the fiber matrix comprising pulping fibers and a fatty acid or its salt, ester, amide, derivative or any combination thereof distributed in the fiber matrix. In some embodiments, the composition may further include an internal sizing agent, such as an alkyl ketene dimer; a polysaccharide; a surfactant; a filler; an acid or any combination thereof.

[0007] In some embodiments, the fibers may include cellulose fibers. In some embodiments, the fiber matrix is ​​water and oil resistant when compressed and heated.

[0008] Described herein is a method for preparing a fibrous matrix described herein, the method comprising blending pulped fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix. In some embodiments, the method may further comprise blending an internal sizing agent, a filler, or any combination thereof with pulped fibers, water, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids or any combination thereof to produce a slurry.

[0009] Also described herein is a method for preparing a fibrous matrix, the method comprising blending pulped fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming a fibrous matrix. In some embodiments, the method may further comprise blending an acid, an internal sizing agent, a filler, a polysaccharide, a surfactant, or any combination thereof with pulped fibers, water, fatty acids or their salts, esters, amides, derivatives, or any combination thereof to produce a slurry.

[0010] In some embodiments, the fibrous matrices described herein are oil and water resistant.

[0011] Also described are articles made using the fibrous substrates described herein and the methods described herein. The articles may include food containers such as boxes, cups, clamshells, plates, bowls, trays, cartons, envelopes, sacks, bags, pouches, liners, separators, wrappers, films, sheets, or cushioning materials.

[0012] The details of one or more embodiments of the present disclosure are set forth in the following drawings and description. Other features, objects, and advantages of the present disclosure will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A schematic diagram of preparing oil-resistant and water-resistant articles is shown.

[0014] Figure 2 A schematic diagram of preparing an exemplary oil-resistant and water-resistant composite material is shown.

[0015] Figure 3 The steps for preparing an exemplary oil-resistant and water-resistant composite material using a water-insoluble acid-insoluble polysaccharide are shown.

[0016] Figure 4The steps for preparing an exemplary oil-resistant and water-resistant composite material using a water-insoluble acid-soluble polysaccharide are shown.

[0017] Figure 5 Steps for preparing exemplary oil-resistant and water-resistant composite materials using acid-soluble polysaccharides and water-soluble polysaccharides are shown.

[0018] Figure 6 The steps for preparing an exemplary oil-resistant and water-resistant composite material using fatty acid salts and polysaccharides are shown.

[0019] Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION

[0020] Several embodiments of the present disclosure have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the present invention. Therefore, other embodiments are within the scope of the following claims.

[0021] definition

[0022] In order to facilitate understanding of the disclosure set forth herein, some terms are defined below. Unless otherwise defined, all technical terms and scientific terms used herein generally have the same meaning as those generally understood by those of ordinary skill in the art to which the disclosure belongs. Publications cited herein and the materials cited therein are specifically incorporated by reference.

[0023] General Definition

[0024] As used in this specification and the following claims, the terms "comprise" (and forms, derivatives or variations thereof, such as "comprising" and "comprises") and "include" (and forms, derivatives or variations thereof, such as "including" and "includes") are inclusive (i.e., open-ended) and do not exclude additional elements or steps. For example, when the terms "comprise" and / or "comprising" are used in this specification, the presence of the features, integers, steps, operations, elements and / or components is indicated, but the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof is not excluded. Unless otherwise indicated, all numbers used in the specification and claims indicating quantities of ingredients, reaction conditions, geometric shapes, dimensions and the like should at least be understood to be interpreted in light of the number of significant figures and ordinary rounding techniques, and not to attempt to limit the scope of the claims by the application of the doctrine of equivalents.

[0025] Therefore, these terms are not only intended to cover the elements or steps listed, but also may include other elements or steps that are not explicitly listed. In addition, as used herein, when used in conjunction with an element, the term "a / an" and "the" may mean "one", but it is also consistent with the meaning of "one or more", "at least one" and "one or more than one". Therefore, in the absence of more constraints, an element starting with "a / an" does not exclude the presence of other identical elements.

[0026] In this article, ranges can be expressed as from "about" a specific value and / or to "about" another specific value. "About" means within 5% of the value, such as within 4%, 3%, 2% or 1% of the value. When expressing such a range, another aspect includes from the specific value and / or to the other specific value. Similarly, when a value is expressed as an approximation by using the antecedent "about", it should be understood that the specific value forms another aspect. It should be further understood that the endpoints of each range are significant relative to the other endpoint and independently of the other endpoint. It should also be understood that many values ​​are disclosed herein, and in addition to the value itself, each value is also disclosed herein as "about" the specific value. For example, if the value "10" is disclosed, "about 10" is also disclosed. Ranges can be interpreted as including the beginning and end of the range. For example, a range of 10% to 20% (i.e., a range of 10%-20%) can include 10% and also include 20%, and include percentages of 10% to 20%, unless otherwise expressly stated herein.

[0027] As used herein, the terms "may," "optionally," and "may optionally" are used interchangeably and are meant to include instances where a condition occurs as well as instances where the condition does not occur. Thus, for example, the statement that a formulation "may include an excipient" is meant to include instances where the formulation includes the excipient as well as instances where the formulation does not include the excipient.

[0028] It should be understood that when combinations, subsets, groups, etc. of elements are disclosed (e.g., combinations of components in a composition, or combinations of steps in a method), while specific reference to each of the various individual and collective combinations and arrangements of these elements may not be explicitly disclosed, each is specifically contemplated and described herein.

[0029] Composition

[0030] The present invention provides a fibrous matrix, the fibrous matrix includes pulping fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof distributed in the fibrous matrix. In some embodiments, the fibrous matrix may include pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof distributed in the fibrous matrix, and acids. In some embodiments, the fibrous matrix may include pulping fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives or any combination thereof distributed in the fibrous matrix. In some embodiments, the fibrous matrix may include pulping fibers, polysaccharides, and acids distributed in the fibrous matrix.

[0031] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0032] In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, anionic polysaccharides, non-ionizable polysaccharides, or any combination thereof, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, anionic polysaccharides, non-ionizable polysaccharides, or any combination thereof, and acids, or salts, esters, amides, derivatives, or any combination thereof, distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, anionic polysaccharides, non-ionizable polysaccharides, or any combination thereof, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, anionic polysaccharides, non-ionizable polysaccharides, or any combination thereof, and acids, or salts, esters, amides, derivatives, or any combination thereof, distributed within the fibrous matrix.

[0033] In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, and fatty acids or salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, fatty acids or salts, esters, amides, derivatives or any combination thereof distributed within the fibrous matrix, and acids. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, and fatty acids or salts, esters, amides, derivatives or any combination thereof distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, cationic polysaccharides, and acids distributed within the fibrous matrix.

[0034] In some embodiments, the fibrous matrix includes pulping fibers, non-ionizable polysaccharides, and fatty acids or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, non-ionizable polysaccharides, fatty acids or salts, esters, amides, derivatives, or any combination thereof, distributed within the fibrous matrix, and acids. In some embodiments, the fibrous matrix includes pulping fibers, non-ionizable polysaccharides, and fatty acids or salts, esters, amides, derivatives, or any combination thereof, distributed within the fibrous matrix. In some embodiments, the fibrous matrix includes pulping fibers, non-ionizable polysaccharides, and acids distributed within the fibrous matrix.

[0035] In some embodiments, the fibrous matrix includes pulping fibers, anionic polysaccharides, and fatty acids or salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof distributed in the fibrous matrix. In some embodiments, the fibrous matrix may include pulping fibers, anionic polysaccharides, fatty acids or salts, esters, amides, derivatives or any combination thereof distributed in the fibrous matrix, and acids. In some embodiments, the fibrous matrix may include pulping fibers, anionic polysaccharides, and fatty acids or salts, esters, amides, derivatives or any combination thereof distributed in the fibrous matrix. In some embodiments, the fibrous matrix may include pulping fibers, anionic polysaccharides, and acids distributed in the fibrous matrix.

[0036] In some embodiments, when the fibrous matrix includes pulping fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further include an internal sizing agent, a filler, or any combination thereof.

[0037] In some embodiments, when the fibrous matrix comprises pulped fibers, polysaccharides, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent. In some embodiments, polysaccharides and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise a filler. In some embodiments, when the fibrous matrix comprises pulped fibers, polysaccharides, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent and a filler.

[0038] In some embodiments, when the fibrous matrix comprises pulping fibers, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent. In some embodiments, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise a filler. In some embodiments, when the fibrous matrix comprises pulping fibers, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent and a filler.

[0039] In some embodiments, the sum of the weight percent concentrations of all polysaccharides and all fatty acids, or salts, esters, amides, derivatives, or any combination thereof, present in the fibrous matrix may be at least greater than 5% (e.g., at least 10%, at least 20%, at least 30%, at least 40%, or at least 50%). In some embodiments, the sum of the weight percent concentrations of all polysaccharides and all fatty acids, or salts, esters, amides, derivatives, or any combination thereof, present in the fibrous matrix may be 55% or less (e.g., 50% or less, 40% or less, 30% or less, 20% or less, or 10% or less).

[0040] The sum of the weight percent concentrations of all polysaccharides and all fatty acids, or salts, esters, amides, derivatives, or any combination thereof, present in the fiber matrix can range from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the sum of the weight percent concentrations of all polysaccharides and all fatty acids, or salts, esters, amides, derivatives, or any combination thereof, present in the fiber matrix can range from greater than 5% to 55%, (e.g., greater than 5% to 50%, greater than 5% to 45%, greater than 5% to 40%, greater than 5% to 35%, greater than 5% to 30%, greater than 5% to 25%, greater than 5% to 20%, greater than 5% to 15%, greater than 5% to 10%, 10% to 50%, 10% to 55%, 10% to 5 % to 45%, 10% to 40%, 10% to 35%, 10% to 30%, 10% to 25%, 10% to 20%, 20% to 55%, 20% to 50%, 20% to 45%, 20% to 40%, 20% to 35%, 20% to 30%, 20% to 25%, 30% to 55%, 30% to 50%, 30% to 45%, 30% to 40%, 30% to 35%, 40% to 55%, 40% to 50%, 40% to 45% or 50% to 55%).

[0041] For example, in some embodiments, when the fibrous matrix includes pulping fibers, an acid and a cationic polysaccharide, the fibrous matrix can further include fatty acids or their salts, esters, amides, derivatives, or any combination thereof, internal sizing agents, fillers, anionic polysaccharides, or any combination thereof.

[0042] Also provided herein is a fibrous matrix comprising pulped fibers and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof distributed within the fibrous matrix.

[0043] In some embodiments, when the fiber matrix includes pulping fibers and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, the fiber matrix may further include an internal sizing agent, a filler, a polysaccharide, an acid, a surfactant, or any combination thereof. In some embodiments, the polysaccharide may be a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof. In some embodiments, when the fiber matrix includes pulping fibers and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, the fiber matrix may further include an internal sizing agent. In some embodiments, when the fiber matrix includes pulping fibers and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, the fiber matrix may further include a filler. In some embodiments, when the fiber matrix includes pulping fibers and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, the fiber matrix may further include a surfactant. In some embodiments, when the fiber matrix includes pulping fibers and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, the fiber matrix may further include an acid. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent, a filler, a polysaccharide, and a surfactant. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent, a filler, and a surfactant. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent and a surfactant. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise a filler and a surfactant. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise an internal sizing agent and a filler. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, fillers, polysaccharides, and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, fillers, and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, and surfactants.In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, fillers, and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, and fillers. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids and internal sizing agents. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids and fillers. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids and polysaccharides.

[0044] In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, fillers, cationic polysaccharides, and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, internal sizing agents, cationic polysaccharides, and surfactants. In some embodiments, when the fibrous matrix comprises pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, the fibrous matrix may further comprise acids, fillers, cationic polysaccharides, and surfactants.

[0045] In some embodiments, the fiber matrix does not include fluorocarbons or non-compostable synthetic polymers; or adds an oil and grease resistant coating.

[0046] acid

[0047] Suitable acids may include, but are not limited to, hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, citric acid, oxalic acid, uric acid, tartaric acid, or any combination thereof.

[0048] In some embodiments, the acid can be present in the fibrous matrix at a concentration of at least 0.1% by weight (e.g., at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90%) of the polysaccharide. In some embodiments, the acid can be present in the fibrous matrix at a concentration of 100% by weight or less (e.g., 90% by weight or less, 80% by weight or less, 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 1% by weight or less, or 0.5% by weight or less) of the polysaccharide.

[0049] The acid can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the acid can be present in a concentration ranging from 0.1% to 100% by weight (e.g., 0.1% to 90%, 0.1% to 80%, 0.1% to 70%, 0.1% to 60%, 0.1% to 50%, 0.1% to 40%, 0.1% to 30%, 0.1% to 20%, 0.1% to 10%, 0.1% to 5%, 0.1% to 100%, 1% to 90%, 1% to 80%, 1% to 100% by weight) of the polysaccharide. % to 70 wt %, 1 wt % to 60 wt %, 1 wt % to 50 wt %, 1 wt % to 40 wt %, 1 wt % to 30 wt %, 1 wt % to 20 wt %, 1 wt % to 10 wt %, 1 wt % to 5 wt %, 10 wt % to 100 wt %, 10 wt % to 90 wt %, 10 wt % to 80 wt %, 10 wt % to 70 wt %, 10 wt % to 60 wt %, 10 wt % to 50 wt %, 10 wt % to 40 wt %, 10 wt % to 30 wt %, 10 wt % to 20 wt %, 20 wt % to 100 wt %, 20 wt % to 90 wt %. %, 20 wt % to 80 wt %, 20 wt % to 70 wt %, 20 wt % to 60 wt %, 20 wt % to 50 wt %, 20 wt % to 40 wt %, 20 wt % to 30 wt %, 30 wt % to 100 wt %, 30 wt % to 90 wt %, 30 wt % to 80 wt %, 30 wt % to 70 wt %, 30 wt % to 60 wt %, 30 wt % to 50 wt %, 30 wt % to 40 wt %, 40 wt % to 100 wt %, 40 wt % to 90 wt %, 40 wt % to 80 wt %, 40 wt % to 70 wt %, 40 wt % to % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 70 wt % to 100 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, 60 wt % to 100 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 80 wt % to 100 wt %, 80 wt % to 90 wt %, or 90 wt % to 100 wt %).

[0050] Polysaccharides

[0051] Suitable polysaccharides may include, but are not limited to, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, modified polysaccharides, or any combination thereof. The modified polysaccharides may be prepared by physically, enzymatically, or chemically changing the inherent properties of the polysaccharide.

[0052] Examples of starches are corn starch, potato starch, wheat starch, rice starch, tapioca starch, arrowroot starch, sorghum starch, sago starch, pea starch, banana starch, chayote starch, coconut starch, chemically modified starch, partially gelatinized starch, pregelatinized high amylose starch, nanoparticle starch or dry starch polyelectrolyte complexes, and the like.

[0053] In some embodiments, the polysaccharide may be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fibrous matrix. In some embodiments, when the fibrous matrix includes pulping fibers, a polysaccharide and a fatty acid or a salt, ester, amide, derivative, or any combination thereof, an acid, or any combination thereof, the polysaccharide may be present in a concentration of 20% by weight or less (e.g., 15% by weight or less, 10% by weight or less, 5% by weight or less) of the fibrous matrix.

[0054] The polysaccharide can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the polysaccharide can be present in a concentration of 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20%) of the fibrous matrix.

[0055] Cationic polysaccharides

[0056] Suitable cationic polysaccharides may include, but are not limited to, chitin, chitosan, partially deacetylated chitin, cationic starch, cationic cellulose, cationic dextran, cationic guar gum, or any combination thereof. It is well known that various cationic polysaccharides can be produced by modifying starch and other polysaccharides by chemical derivatization. Cationic polysaccharides, i.e., polysaccharides modified to carry a positive charge. As used herein, the term "cationic polysaccharide" refers to a modified polysaccharide containing one or more cationic groups, cationizable groups, or mixtures thereof. The one or more cationic groups may include quaternary amines, tertiary amines, secondary amines, other nitrogen-containing, positively charged groups, sulfonium groups, and phosphorus groups, as well as any other cationic groups that can be substituted onto starch without causing starch degradation. It is well known that the cationicity of primary, secondary, and tertiary amines depends on the pH of the system. At low pH levels, these amines tend to be strongly cationic. At high pH levels, these amines will not ionize. On the other hand, quaternary amines are cationic under all pH conditions. "Cationic polysaccharide" means a polysaccharide with a positive charge that causes attraction or migration to the cathode. The term "cationic polysaccharide" as used in the specification and claims herein means a polysaccharide product containing any of the cationic groups listed herein and their mixtures. Such polysaccharides are characterized in that the bases used to prepare the derivatives have a higher cationicity. The presence of other modifying groups (such as anionic groups) on the polysaccharide will change the degree of cationicity of the product, depending on the pH level of the system. Examples of cationic polysaccharides are described in U.S. Patent No. 6,193,843, which is hereby incorporated by reference in its entirety. In some embodiments, the cationic polysaccharide may include chitosan. In some embodiments, the cationic polysaccharide may include chitin. In some embodiments, the cationic polysaccharide may include cationic starch.

[0057] The term "cationic starch" may also include modified starches or mixtures thereof containing one or more cationic groups. Modified starches may be prepared by physically, enzymatically or chemically changing the intrinsic properties of starch so that it has a cationic charge. Examples of cationic starches are described in U.S. Patents Nos. 6,193,843, 3,354,034, 3,666,751, 4,060,683, 2,989,520 and 3,077,469, which are hereby incorporated by reference in their entirety. In some embodiments, cationic starches may be defined as follows:

[0058]

[0059] in

[0060] R is independently selected from H or

[0061] X is N, S or P;

[0062] R' is selected from substituted or unsubstituted alkyl, alkylene, hydroxyalkyl or hydroxyalkylene;

[0063] R 1 and R 2 are independently selected from substituted or unsubstituted hydrogen, alkyl, alkylene, hydroxyalkyl, hydroxyalkylene, -R'-Y, Aryl or aralkyl;

[0064] n is an integer from 10 to 1000;

[0065] a is an integer from 0 to 3; and

[0066] Y is selected from -OH, -NH2, -NHR', -NR'R' or -NR'R'R',

[0067] At least one of the R

[0068] In some embodiments, cationic starch can be defined by:

[0069]

[0070] in

[0071] R is independently selected from H or

[0072] X is N, S or P;

[0073] R' is selected from substituted or unsubstituted alkyl, alkylene, hydroxyalkyl or hydroxyalkylene;

[0074] R 1 and R 2 are independently selected from substituted or unsubstituted hydrogen, alkyl, alkylene, hydroxyalkyl, hydroxyalkylene, -R'-Y, Aryl or aralkyl;

[0075] n is an integer from 10 to 1000;

[0076] a is an integer from 0 to 3; and

[0077] Y is selected from -OH, -NH2, -NHR', -NR'R' or -NR'R'R',

[0078] At least one of the R

[0079] In some embodiments, the cationic starch may be

[0080]

[0081] in

[0082] R is

[0083] X is N;

[0084] R' is selected from substituted or unsubstituted alkyl, alkylene, hydroxyalkyl or hydroxyalkylene;

[0085] R 1 and R 2 are independently selected from substituted or unsubstituted hydrogen, alkyl, alkylene, hydroxyalkyl, hydroxyalkylene, -R'-Y, Aryl or aralkyl;

[0086] n is an integer from 10 to 1000;

[0087] a is an integer from 0 to 3; and

[0088] Y is selected from -OH, -NH2, -NHR', -NR'R' or -NR'R'R.

[0089] In some embodiments, the cationic starch may be

[0090]

[0091] in

[0092] R is

[0093] X is N;

[0094] R' is selected from substituted or unsubstituted alkyl, alkylene, hydroxyalkyl or hydroxyalkylene;

[0095] R 1 and R 2 are independently selected from substituted or unsubstituted hydrogen, alkyl, alkylene, hydroxyalkyl, hydroxyalkylene, -R'-Y, Aryl or aralkyl;

[0096] n is an integer from 10 to 1000;

[0097] a is an integer from 0 to 3; and

[0098] Y is selected from -OH, -NH2, -NHR', -NR'R' or -NR'R'R.

[0099] In some embodiments, the cationic polysaccharide may include chitosan. In some embodiments, the cationic polysaccharide may include chitin. In some embodiments, the cationic polysaccharide may include partially deacetylated chitin. In some embodiments, the cationic polysaccharide may include cationic starch.

[0100] In some embodiments, the cationic polysaccharide can be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fibrous matrix. In some embodiments, the cationic polysaccharide can be present in a concentration of 20% by weight or less (e.g., 15% or less, 10% or less, 5% or less) of the fibrous matrix.

[0101] The cationic polysaccharide can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the cationic polysaccharide can be present in a concentration of 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20%) of the fibrous matrix.

[0102] In some embodiments, the cationic starch may be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fiber matrix. In some embodiments, the cationic starch may be present in a concentration of 20% by weight or less (e.g., 15% or less, 10% or less, or 5% or less) of the fiber matrix.

[0103] Cationic starch can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the cationic polysaccharide can be present in a concentration of 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20% by weight) of the fibrous matrix.

[0104] In some embodiments, chitosan can be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fiber matrix. In some embodiments, chitosan can be present in a concentration of 20% by weight or less (e.g., 15% or less, 10% or less, or 5% or less) of the fiber matrix.

[0105] Chitosan can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, chitosan can be present in a concentration ranging from 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20%) of the fibrous matrix.

[0106] Anionic polysaccharides

[0107] In some embodiments, the fibrous matrix may further include anionic polysaccharides. Suitable anionic polysaccharides may include, but are not limited to, heparin, hyaluronic acid, carrageenan, alginic acid, alginate, chondroitin sulfate, or any combination thereof.

[0108] In some embodiments, the anionic polysaccharide can be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fibrous matrix. In some embodiments, the anionic polysaccharide can be present in a concentration of 20% by weight or less (e.g., 15% or less, 10% or less, 5% or less) of the fibrous matrix.

[0109] The anionic polysaccharide can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the anionic polysaccharide can be present in a concentration of 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20%) of the fibrous matrix.

[0110] Non-ionizable polysaccharides

[0111] Suitable non-ionizable polysaccharides may include, but are not limited to, starch, cellulose, hemicellulose, dextran, guar gum, tera gum, glucomannan, curdlan, or any combination thereof.

[0112] In some embodiments, the non-ionizable polysaccharide may be present in a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, or at least 15%) of the fiber matrix. In some embodiments, the non-ionizable polysaccharide may be present in a concentration of 20% by weight or less (e.g., 15% or less, 10% or less, 5% or less) of the fiber matrix.

[0113] The non-ionizable polysaccharide can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the non-ionizable polysaccharide can be present in a concentration ranging from 1% to 20% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 20%, 10% to 15%, or 15% to 20% by weight) of the fibrous matrix.

[0114] Fatty acids or their salts, esters, amides, derivatives or any combination thereof

[0115] As used herein, the term "fatty acid" is intended to represent a carboxylic acid with at least 8 carbon atoms. In one example, a fatty acid or its salt or ester can include at least 9, at least 10, at least 12, at least 14, at least 16, at least 18 or at least 20 carbon atoms. In some specific examples, a fatty acid or its ester can contain 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44 or 45 carbon atoms. In other examples, the fatty acid or its salt or ester can comprise a mixture of fatty acids or their esters having a range of carbon atoms. For example, the fatty acid or its ester can comprise 8 to 40, 10 to 40, 12 to 38, 14 to 36, 16 to 34, 18 to 32, or 20 to 30 carbon atoms.

[0116] The term "fatty acid" is also understood to mean that the carboxyl group can be in protonated or deprotonated form (i.e., RCO2- and RCO2H, where R is a hydrocarbon chain). Thus, phrases such as glycerol esters with saturated fatty acids are understood to mean molecules in which the carboxyl portion of a saturated fatty acid is bound to a glycerol molecule via an ester bond. This convention and nomenclature is commonly used by those skilled in the art.

[0117] The fatty acid or its salt or ester can be a saturated fatty acid, an unsaturated fatty acid or a mixture of a saturated fatty acid and an unsaturated fatty acid. As used herein, the term "saturated" is intended to mean that the molecule or residue does not contain a carbon-carbon double bond or triple bond. As used herein, the term "unsaturated" is intended to mean that the molecule or residue contains at least one carbon-carbon double bond or triple bond.

[0118] Examples of specific saturated fatty acids include, but are not limited to, capric acid (C10), lauric acid (C12), myristic acid (C14), palmitic acid (C16), margaric acid (C17), stearic acid (C18), arachidic acid (C20), behenic acid (C22), lignoceric acid (C24), cerotic acid (C26), montanic acid (C28), and melissic acid (C30), including branched and substituted derivatives thereof.

[0119] Examples of unsaturated fatty acids may include a carbon-carbon double bond. Examples of such monounsaturated fatty acids include, but are not limited to, oleic acid, palmitoleic acid, myristic acid, petroselinic acid, linoleic acid, vaccenic acid, gadoleic acid, cetoleic acid, erucic acid, shark acid, ximenolenic acid, triacontanol. Unsaturated fatty acids may include at least two unsaturated bonds. In some examples, unsaturated fatty acids may include at least one pair of methylene-interrupted unsaturated bonds. "Methylene-interrupted unsaturated bonds" means that a carbon-carbon double bond or triple bond is separated from another carbon-carbon double bond or triple bond by at least one methylene group (i.e., CH2). Specific examples of unsaturated fatty acids containing at least one pair of methylene interrupted unsaturated bonds include, but are not limited to, n-1 family derived from 9, 12, 15-16:3; n-2 family derived from 9, 12, 15-17:3, 15:3, 17:3, 17:4, 20:4; n-3 family derived from 9, 12, 15-18:3, 15:2, 15:3, 15:4, 16:3, 16:4, 18:3 (linolenic acid), 18:4, 18:5, 20:2, 20:3, 20:4 ; n-3 family derived from 20:5 (EPA), 21:5, 22:3, 22:5 (DPA), 22:6 (DHA), 24:3, 24:4, 24:5, 24:6, 26:5, 26:6, 28:7, 30:5; n-4 family derived from 9, 12-16:2, 16:2, 16:3, 18:2, 18:3; derived from 9, 12-17:2, 15:2, 17:2, 17:3, 19:2, 19:4, 20:3, 20:4 n-5 family derived from 21:4, 21:5; n-6 family derived from 9, 12-18:2, 15:2, 16:2, 18:2 (linoleic acid), 18:3 (linolenic acid); 20:2, 20:3, 20:4 (arachidonic acid), 22:2, 22:3, 22:4 (docosatetraenoic acid), 22:5, 24:2, 24:4, 25:2, 26:2, 30:4; n-6 family derived from 9- n-7 family derived from 9-17:1, 15:2, 16:2, 17:2, 18:2, 19:2; n-8 family derived from 9-18:1, 17:2, 18:2, 20:2, 20:3, 22:3, 22:4; n-11 family 19:2 and n-12 family 20:2. (These compounds are first identified by reference to the "nx family" where x is the position where the first double bond in the fatty acid begins. The numbering scheme starts at the end of the fatty acid, for example where the terminal CH3 group is designated as position 1. The next number represents the total number of carbon atoms in the fatty acid. The third number (after the colon) represents the total number of double bonds in the fatty acid.Thus for example in the n-1 family, 16:3 refers to a 16 carbon long fatty acid having 3 double bonds, each separated by a methylene group, with the first double bond beginning at position 1, ie the end of the fatty acid).

[0120] In some embodiments, the fatty acids can include, but are not limited to, oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, oleic acid, palmitoleic acid, myristoleic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenoleic acid, triacontanic acid, or any combination thereof.

[0121] In some embodiments, fatty acid salts may include, but are not limited to, ammonium salts of fatty acids, sodium salts of fatty acids, potassium salts of fatty acids, calcium salts of fatty acids, zinc salts of fatty acids, magnesium salts of fatty acids, iron salts of fatty acids, manganese salts of fatty acids, aluminum salts of fatty acids, or any combination thereof.

[0122] In some embodiments, the fatty acid esters can include, but are not limited to, oleate, caprylate, nonanoate, caprate, laurate, myristate, palmitate, stearate, lignocerate, behenate, montanate, melissate, palmitoleate, myristoleate, linoleate, linolenate, petroselinate, isooleate, gadoleate, cetylene, erucate, shalanate, ximenylene, triaconate, or any combination thereof. For example, oleyl oleate, oleyl laurate, oleyl caprylate, oleyl palmitate, oleyl citrate, oleyl behenate, oleyl stearate, lauryl stearate, lauryl oleate, lauryl laurate, lauryl caprylate, lauryl palmitate, lauryl citrate, lauryl behenate, palmitol oleate, palmitol laurate, palmitol stearate, palmitol caprylate, palmitol palmitate, palmitol citrate, palmitol behenate, behenyl stearate, behenyl oleate, behenyl laurate, behenyl caprylate, behenyl palmitate, behenyl citrate, behenyl behenate, myristyl stearate, myristyl oleate Esters, myristyl laurate, myristyl caprylate, myristyl palmitate, myristyl citrate, myristyl behenate, stearyl oleate, stearyl caprylate, stearyl nonanoate, stearyl caprate, stearyl laurate, stearyl myristate, stearyl lignocerate, stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, arachidyl linoleate, arachidyl linolenate, arachidyl myristoleate, arachidyl oleate, arachidyl palmitate, behenyl linoleate, behenyl linoleate, behenyl myristoleate, elaidoyl palmitate, gondoyl linoleate, gondoyl linoleatelinolenate), lauryl linoleate, lauryl linolenate, lauryl myristoleate, lauryl palmitoleate, linolenyl arachidate, linolenyl behenate, linolenyl laurate, linolenyl linoleate, linolenyl linoleate, linolenyl myristate, linolenyl oleate, linolenyl palmitate, linolenyl palmitoleate, linolenyl stearate, linoleyl arachidate, linoleyl arachidonic acid, linoleyl behenate , linoleyl laurate, linoleyl linoleate, linoleyl linolenate, linoleyl myristate, linoleyl myristoleate, linoleyl oleate, linoleyl palmitate, linoleyl palmitoleate, linoleyl stearate, myristyl arachidate, myristyl arachidonic acid, myristyl behenate, myristyl laurate, myristyl linoleate, myristyl linoleate, myristyl linolenate, myristyl myristate, nutmeg Myristyl oleate, myristyl oleate, myristyl palmitate, myristyl palmitoleate, myristyl stearate, myristyl linoleate, myristyl linoleate, oleyl arachidate, oleyl arachidonic acid, oleyl linoleate, oleyl linoleate, oleyl myristoleate, oleyl palmitoleate, oleyl arachidate, palmitoleyl arachidonic acid, palmitoleyl behenate, palmitoleyl laurate, Palmitoleyl linoleate, palmitoleyl linolenate, palmitoleyl myristate, palmitoleyl myristoleate, palmitoleyl oleate, palmitoleyl palmitate, palmitoleyl stearate, palmitoleyl linoleate, palmitoleyl linoleate, palmitoleyl linoleate, palmitoleyl myristoleate, palmitoleyl palmitoleate, palmitoleyl stearate, stearyl linoleate, stearyl linoleate, stearyl linoleate, stearyl linoleate, stearyl myristoleate or any combination thereof.

[0123] In some embodiments, fatty acid amides may include, but are not limited to, oleamide, caprylic acid amide, nonanoic acid amide, capric acid amide, lauric acid amide, myristic acid amide, palmitic acid amide, stearic acid amide, wood wax acid amide, behenic acid amide, montanic acid amide, melissinic acid amide, palmitic acid amide, myristic acid amide, linoleic acid amide, linolenic acid amide, petroselinic acid amide, isoleic acid amide, gadoleic acid amide, cetyl olefinic acid amide, erucic acid amide, shark amide, simmondsia chinensis olefinic acid amide, triacontenic acid amide, or any combination thereof. For example, stearic acid amide, ethylene bis stearic acid amide, oleamide, ethylene bis oleic acid amide, or any combination thereof.

[0124] In some embodiments, fatty acid or its salt, ester, amide, derivative or any combination thereof can include zinc stearate, magnesium stearate, stearic acid, aluminum stearate or any combination thereof. In some embodiments, fatty acid or salt, ester, amide or derivative can include zinc stearate. In some embodiments, fatty acid or salt, ester, amide or derivative can include stearic acid.

[0125] In some embodiments, when present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, may be present at a concentration of at least 0.1% by weight (e.g., at least 0.5%, at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, or at least 45% by weight) of the fibrous matrix. In some embodiments, when the fibrous matrix includes pulping fibers, an acid, and a cationic polysaccharide, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, may be present at a concentration of 50% or less by weight (e.g., 45% or less, 40% or less, 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 5% or less, 1% or less, or 0.5% or less) of the fibrous matrix.

[0126] When present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in a concentration ranging from 0.1% to 50% by weight (e.g., 0.1% to 1%, 0.1% to 5%, 0.1% to 10%, 0.1% to 15%, 0.1% to 20%, 0.1% to 25%, 0.1% to 30%, 0.1% to 35%, 0.1% to 40% by weight) of the fibrous substrate. % by weight, 0.1% to 45% by weight, 0.5% to 1% by weight, 0.5% to 5% by weight, 0.5% to 10% by weight, 0.5% to 15% by weight, 0.5% to 20% by weight, 0.5% to 25% by weight, 0.5% to 30% by weight, 0.5% to 35% by weight, 0.5% to 40% by weight, 0.5% to 45% by weight, 0.5% to 50% by weight, 1% to 5%, 1% to 5% by weight % to 10 wt %, 1 wt % to 15 wt %, 1 wt % to 20 wt %, 1 wt % to 25 wt %, 1 wt % to 30 wt %, 1 wt % to 35 wt %, 1 wt % to 40 wt %, 1 wt % to 45 wt %, 1 wt % to 50 wt %, 5 wt % to 10 wt %, 5 wt % to 15 wt %, 5 wt % to 20 wt %, 5 wt % to 25 wt %, 5 wt % to 30 wt %, 5 wt % to 35 wt %, 5 wt % to 40 wt %, % to 45 wt %, 5 wt % to 50 wt %, 10 wt % to 15 wt %, 10 wt % to 20 wt %, 10 wt % to 30 wt %, 10 wt % to 40 wt %, 10 wt % to 50 wt %, 20 wt % to 30 wt %, 20 wt % to 40 wt %, 20 wt % to 50 wt %, 30 wt % to 40 wt %, 30 wt % to 40 wt %, 30 wt % to 50 wt %, or 40 wt % to 50 wt %).

[0127] For example, in some embodiments, when present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, can be present in a concentration of at least 0.1% by weight (e.g., at least 0.5%, at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, or at least 9% by weight) of the fibrous matrix. In some embodiments, when the fibrous matrix includes pulping fibers, an acid, and a cationic polysaccharide, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, can be present in a concentration of 10% by weight or less (e.g., 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or 0.5% by weight or less) of the fibrous matrix.

[0128] When present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in a concentration ranging from 0.1% to 10% by weight (e.g., 0.1% to 1%, 0.1% to 2%, 0.1% to 3%, 0.1% to 4%, 0.1% to 5%, 0.1% to 6%, 0.1% to 7%, 0.1% to 8%, 0.1% to 9%, 0.5% to 1%, 0.5% to 2%, 0.5% to 4%, 0.5% to 5%, 0.1% to 6%, 0.1% to 7%, 0.1% to 8%, 0.1% to 9%, 0.5% to 1%, 0.5% to 2%, 0.5% to 3%, 0.1% to 4%, 0.1 ... % to 3 wt%, 0.5 wt% to 4 wt%, 0.5 wt% to 5 wt%, 0.5 wt% to 6 wt%, 0.5 wt% to 7 wt%, 0.5 wt% to 8 wt%, 0.5 wt% to 9 wt%, 0.5 wt% to 10 wt%, 1 wt% to 2 wt%, 1 wt% to 3 wt%, 1 wt% to 4 wt%, 1 wt% to 5 wt%, 1 wt% to 6 wt%, 1 wt% to 7 wt%, 1 wt% to 8 wt%, 1 wt% to 9 wt%, 1 wt% to 10 wt%, 2 wt% to 3 wt%, 2 wt% to 4 wt%. % to 4 wt%, 2 wt% to 5 wt%, 2 wt% to 6 wt%, 2 wt% to 7 wt%, 2 wt% to 8 wt%, 2 wt% to 9 wt%, 2 wt% to 10 wt%, 3 wt% to 4 wt%, 3 wt% to 5 wt%, 3 wt% to 6 wt%, 3 wt% to 7 wt%, 3 wt% to 8 wt%, 3 wt% to 9 wt%, 3 wt% to 10 wt%, 4 wt% to 5 wt%, 4 wt% to 6 wt%, 4 wt% to 7 wt%, 4 wt% to 8 wt%, 4 wt% to 9 wt%, 4 wt% to 1 % to 8 wt %, 7 wt % to 9 wt %, 7 wt % to 10 wt %, 8 wt % to 9 wt %, 8 wt % to 10 wt %, or 9 wt % to 10 wt %)).

[0129] In some other embodiments, for example, when the fibrous matrix includes pulping fibers and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof, and optionally an internal sizing agent, filler, surfactant, or any combination thereof, the fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof may be present in a concentration of at least 15% by weight (e.g., at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, or at least 45% by weight) of the fibrous matrix. In some embodiments, when the fibrous matrix includes pulping fibers and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof, the fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof may be present in a concentration of 50% by weight or less (e.g., 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less) of the fibrous matrix.

[0130] When the fibrous matrix includes pulping fibers and fatty acids, or salts, esters, amides, derivatives, or any combination thereof, then the fatty acids, or salts, esters, amides, derivatives, or any combination thereof, may be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present at a concentration of 15% to 50% by weight (e.g., 15% to 20%, 15% to 25%, 15% to 30%, 15% to 35%, 15% to 40%, 15% to 45%, 20% to 50%, 20% to 45%, 20% to 40%, 20% to 35%, 20% to 30%, 20% to 25%, 30% to 40%, 30% to 50%, or 40% to 50% by weight) of the fibrous substrate.

[0131] Internal sizing agent

[0132] Suitable internal sizing agents described herein may include, but are not limited to, alkyl ketene dimers, alkenyl ketene dimers, aryl ketene dimers, alkaryl ketene dimers, alkenyl succinic anhydrides, rosins, waxes, stearic anhydride or other fatty acid anhydrides. In some embodiments, the internal sizing agent may include alkyl ketene dimers.

[0133] In some embodiments, the internal sizing agent can be present in a concentration of at least 0.03% by weight (e.g., at least 0.1%, at least 0.5%, at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, or at least 80% by weight) of the fiber matrix. In some embodiments, the internal sizing agent can be present in a concentration of 90% by weight or less (e.g., 80% by weight or less, 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less) of the fiber matrix.

[0134] The internal sizing agent can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the internal sizing agent can be present in a concentration ranging from 0.03% to 90% by weight (e.g., 0.03% to 90% by weight, 0.03% to 80% by weight, 0.03% to 70% by weight, 0.03% to 60% by weight, 0.03% to 50% by weight, 0.03% to 40% by weight, 0.03% to 30% by weight, 0.03% to 20% by weight, 0.03% to 10% by weight, 0.03% to 5% by weight, 0.03% to 10% by weight, 0.03% to 5% by weight, 0.03% to 90% by weight, 1% to 10% by weight, % to 80 wt %, 1 wt % to 70 wt %, 1 wt % to 60 wt %, 1 wt % to 50 wt %, 1 wt % to 40 wt %, 1 wt % to 30 wt %, 1 wt % to 20 wt %, 1 wt % to 10 wt %, 1 wt % to 5 wt %, 5 wt % to 90 wt %, 5 wt % to 80 wt %, 5 wt % to 70 wt %, 5 wt % to 60 wt %, 5 wt % to 50 wt %, 5 wt % to 40 wt %, 5 wt % to 30 wt %, 5 wt % to 20 wt %, 5 wt % to 10 wt %, 10 wt % to 90 wt %, 10 wt % % to 80 wt%, 10 wt% to 70 wt%, 10 wt% to 60 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, 20 wt% to 90 wt%, 20 wt% to 80 wt%, 20 wt% to 70 wt%, 20 wt% to 60 wt%, 20 wt% to 50 wt%, 20 wt% to 40 wt%, 20 wt% to 30 wt%, 30 wt% to 90 wt%, 30 wt% to 80 wt%, 30 wt% to 70 wt%, 30 wt% to 60 wt% %, 30 wt % to 50 wt %, 30 wt % to 40 wt %, 40 wt % to 90 wt %, 40 wt % to 80 wt %, 40 wt % to 70 wt %, 40 wt % to 60 wt %, 40 wt % to 50 wt %, 50 wt % to 90 wt %, 50 wt % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, or 80 wt % to 90 wt %).

[0135] filler

[0136] Suitable filler materials described herein may include, but are not limited to, minerals (eg, calcium carbonate, titanium dioxide, talc, or clay), lignocellulosic particles, or any compostable material (biodegradable or inorganic) that may be used as a filler, or any combination thereof.

[0137] Surfactants

[0138] The term "surfactant" refers to a compound that reduces its surface tension when added to a composition, thereby increasing its diffusion and wetting properties. The surfactant can be an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, an amphoteric surfactant, a nonionic surfactant. Exemplary surfactants can include polymeric surfactants of lignin, starch, and cellulose, such as lignin sulfonate, lignin carboxylate, lignin glyoxylate, amphoteric starch, starch octenyl succinate, carboxymethyl starch, hydroxyethyl starch, carboxymethyl cellulose, hydroxypropyl methylcellulose, polyoxyethylene derivatives of fatty acids, partial esters of sorbitan anhydride, Tween (e.g., Tween 20, Tween 40, Tween 60, Tween 80, etc.), Span (e.g., Span Stearic acid polyoxyl 40 ester, stearic acid polyethylene glycol 50 ester, edetate disodium, glyceryl monooleate, fusidic acid esters, bile salts, octoxynol, ammonium stearate, sodium stearate, potassium stearate, sodium dodecyl sulfate (SDS), cetyltrimethylammonium bromide (CTAB), 4-(5-dodecyl)benzene sulfonate, docusate (sodium dioctyl dibutyrate sulfonate), alkyl ether phosphate or benzalkonium chloride (BAC) or any combination thereof.

[0139] fiber

[0140] The fibers described herein may include cellulose fibers. As used herein, the term "cellulose fibers" means any fiber that incorporates cellulose as a primary component. Cellulose fibers may include, but are not limited to, raw pulp, regenerated (secondary) cellulose fibers, or fiber mixtures containing recombinant cellulose fibers. Cellulose fibers suitable for making the fiber sheets of the present invention include non-wood fibers and wood fibers. Non-wood fibers may be cotton fibers or cotton derivatives, abaca fibers, kenaf fibers, Indian grass fibers, flax fibers, sedge fibers, straw fibers, jute fibers, hemp fibers, bagasse fibers, milkweed floss fibers, and pineapple leaf fibers. Wood fibers may be wood fibers obtained from deciduous trees and conifers, and may be softwood fibers or hardwood fibers. Softwood fibers include northern and southern softwood kraft fibers; and hardwood fibers include eucalyptus, maple, birch, poplar, etc. Papermaking fibers may include naturally occurring pulp-derived fibers and recombinant cellulose fibers, such as lyocell or rayon. The pulp-derived fibers are released from their source material by any of a variety of pulping processes familiar to those skilled in the art. Pulping processes may include kraft pulping, sulfite pulping, polysulfide pulping, soda pulping, and the like. If desired, the pulp may be bleached by chemical methods, including the use of chlorine, chlorine dioxide, oxygen, alkaline peroxides, and the like. Naturally occurring pulp-derived fibers are referred to herein as "pulp-derived" papermaking fibers. The product of the present invention may comprise a blend of conventional fibers (whether derived from virgin pulp or recycled sources) and high-coarseness lignin-rich tubular fibers (such as bleached chemothermomechanical pulp (BCTMP)). Pulp-derived fibers may also include high-yield fibers such as BCTMP as well as thermomechanical pulp (TMP), chemothermomechanical pulp (CTMP), and alkaline peroxide mechanical pulp (APMP).

[0141] The fiber matrix is ​​water and oil resistant when compressed and heated. In some embodiments, the fiber matrix can be hot water resistant, cold water resistant, hot oil resistant, cold oil resistant, or any combination thereof. Oil resistance can be measured by applying 90°C oil to the fiber matrix and evaluating the oil absorption and / or leakage after 2 hours. Water resistance can be measured by applying boiling water to the fiber matrix and evaluating the water absorption and / or leakage after 1 hour.

[0142] method

[0143] Described herein is a method for preparing a fibrous matrix, the method comprising blending pulped fibers, a polysaccharide, and a fatty acid or its salt, ester, amide, derivative, or any combination thereof, an acid, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0144] In some embodiments, a method for preparing a fibrous matrix may include blending pulped fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof with water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0145] In some embodiments, a method for preparing a fibrous matrix may include blending pulped fibers, polysaccharides, and acid and water to produce a slurry; casting the slurry into a wet mat in a product shape; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0146] In some embodiments, a method for preparing a fibrous matrix may include blending pulped fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, an acid, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0147] In some embodiments, the method may further include blending an internal sizing agent, filler, or any combination thereof with pulping fibers, polysaccharides, fatty acids or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry.

[0148] In some embodiments, the method may further include blending the filler material with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry. In some embodiments, the method may further include blending its internal sizing agent with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry. In some embodiments, the method may further include blending its internal sizing agent and filler with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry.

[0149] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0150] In some embodiments, a method for preparing a fibrous matrix may include blending pulped fibers, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0151] In some embodiments, a method for preparing a fibrous matrix may include blending pulped fibers, a cationic polysaccharide, and a fatty acid or its salt, ester, amide, derivative, or any combination thereof, an acid, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0152] In some embodiments, a method for preparing a fibrous matrix may include blending pulping fibers, anionic polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0153] In some embodiments, a method for preparing a fibrous matrix may include blending pulping fibers, non-ionizable polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix.

[0154] Also described herein is a method for preparing a fibrous matrix, the method comprising blending pulped fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry distributed in the slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the fibrous matrix. In some embodiments, the fibrous matrix can be oil resistant and water resistant.

[0155] In some embodiments, the method may further include blending an internal sizing agent, a filler, a polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent and a filler with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a polysaccharide and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the filler, polysaccharide, and surfactant with the pulping fibers, water, and the fatty acid or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0156] In some embodiments, the method may further include blending the acid and filler with the fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, internal sizing agent, filler, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, internal sizing agent and filler with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, filler, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, filler, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry.

[0157] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0158] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0159] In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, a surfactant, an acid, or any combination thereof with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method can further include blending a filler, a nonionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0160] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0161] In some embodiments, the method may further include blending an internal sizing agent, a filler, a cationic polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a cationic polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a cationic polysaccharide and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler, a cationic polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0162] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, an anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, an anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0163] In some embodiments, the method may further include blending an internal sizing agent, filler, anionic polysaccharide, surfactant, acid, or any combination thereof with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, filler, anionic polysaccharide, and surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending anionic polysaccharides and surfactants with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending fillers, anionic polysaccharides, and surfactants with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry.

[0164] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0165] In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a non-ionizable polysaccharide and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler, a non-ionizable polysaccharide, and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry.

[0166] In some embodiments, the acid can be present in the slurry at a concentration of at least 0.1 wt % (e.g., at least 1 wt %, at least 5 wt %, at least 10 wt %, at least 20 wt %, at least 30 wt %, at least 50 wt %, at least 60 wt %, at least 70 wt %, at least 80 wt %, or at least 90 wt %) of the polysaccharide.

[0167] In some embodiments, the acid can be present in the slurry at a concentration of 100 wt % or less (e.g., 90 wt % or less, 80 wt % or less, 70 wt % or less, 60 wt % or less, 50 wt % or less, 40 wt % or less, 30 wt % or less, 20 wt % or less, 10 wt % or less, 5 wt % or less, 1 wt % or less, or 0.5 wt % or less) based on the polysaccharide.

[0168] The acid can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the acid can be present in a concentration ranging from 0.1% to 100% by weight (e.g., 0.1% to 90%, 0.1% to 80%, 0.1% to 70%, 0.1% to 60%, 0.1% to 50%, 0.1% to 40%, 0.1% to 30%, 0.1% to 20%, 0.1% to 10%, 0.1% to 5%, 0.1% to 100%, 1% to 90%, 1% to 80%, 1% to 100% by weight) of the polysaccharide. % to 70 wt %, 1 wt % to 60 wt %, 1 wt % to 50 wt %, 1 wt % to 40 wt %, 1 wt % to 30 wt %, 1 wt % to 20 wt %, 1 wt % to 10 wt %, 1 wt % to 5 wt %, 10 wt % to 100 wt %, 10 wt % to 90 wt %, 10 wt % to 80 wt %, 10 wt % to 70 wt %, 10 wt % to 60 wt %, 10 wt % to 50 wt %, 10 wt % to 40 wt %, 10 wt % to 30 wt %, 10 wt % to 20 wt %, 20 wt % to 100 wt %, 20 wt % to 90 %, 20% to 80% by weight, 20% to 70% by weight, 20% to 60% by weight, 20% to 50% by weight, 20% to 40% by weight, 20% to 30% by weight, 30% to 100% by weight, 30% to 90% by weight, 30% to 80% by weight, 30% to 70% by weight, 30% to 60% by weight, 30% to 50% by weight, 30% to 40% by weight, 40% to 100% by weight, 40% to 90% by weight, 40% to 80% by weight, 40% to 70% by weight, 40% to 50% by weight, % to 60 wt %, 40 wt % to 50 wt %, 50 wt % to 100 wt %, 50 wt % to 90 wt %, 50 wt % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 70 wt % to 100 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, 60 wt % to 100 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 80 wt % to 100 wt %, 80 wt % to 90 wt %, or 90 wt % to 100 wt %).

[0169] In some embodiments, the polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0170] The polysaccharide can be added to the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous substrate.

[0171] In some embodiments, the non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof may be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof may be present in the slurry at a concentration of 40% by weight or less (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0172] The non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof can be added to the slurry in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the polysaccharide can be added in a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0173] In some embodiments, the cationic polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the cationic polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0174] The cationic polysaccharide can be added to the slurry at a concentration ranging from any one of the minimum values ​​described above to any one of the maximum values ​​described above. For example, in some embodiments, the cationic polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous substrate.

[0175] In some embodiments, the anionic polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the anionic polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0176] The anionic polysaccharide can be added to the slurry in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the anionic polysaccharide can be added in a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0177] In some embodiments, the non-ionizable polysaccharide may be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the non-ionizable polysaccharide may be present in the slurry at a concentration of 40% by weight or less (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0178] The non-ionizable polysaccharide can be added to the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the non-ionizable polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0179] In some embodiments, when present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, can be present in the slurry at a concentration of at least 0.1% by weight (e.g., at least 0.5%, at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 60%, or at least 70% by weight) of the fibrous substrate. In some embodiments, when present, the fatty acids or their salts, esters, amides, derivatives, or any combination thereof, may be present in the slurry at a concentration of 80% or less by weight (e.g., 70% or less, 60% or less, 50% or less, 45% or less, 40% or less, 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 5% or less, 1% or less, or 0.5% or less by weight) of the fibrous matrix.

[0180] When present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in the slurry at a concentration ranging from 0.1% to 80% by weight (e.g., 0.1% to 1%, 0.1% to 5%, 0.1% to 10%, 0.1% to 15%, 0.1% to 20%, 0.1% to 25%, 0.1% to 30%, 0.1% to 35%, 0.1% to 40%, 0.1% to 45%, 0.1% to 50% by weight) of the fibrous substrate. %, 0.1 wt % to 60 wt %, 0.1 wt % to 70 wt %, 0.5 wt % to 1 wt %, 0.5 wt % to 5 wt %, 0.5 wt % to 10 wt %, 0.5 wt % to 15 wt %, 0.5 wt % to 20 wt %, 0.5 wt % to 25 wt %, 0.5 wt % to 30 wt %, 0.5 wt % to 35 wt %, 0.5 wt % to 40 wt %, 0.5 wt % to 45 wt %, 0.5 wt % to 50 wt %, 0.5 wt % to 60 wt %, 0.5 wt % to 70 wt %, 0.5% to 80% by weight, 1% to 5% by weight, 1% to 10% by weight, 1% to 15% by weight, 1% to 20% by weight, 1% to 25% by weight, 1% to 30% by weight, 1% to 35% by weight, 1% to 40% by weight, 1% to 45% by weight, 1% to 50% by weight, 1% to 60% by weight, 1% to 70% by weight, 1% to 80% by weight, 5% to 10% by weight, %, 5% to 15% by weight, 5% to 20% by weight, 5% to 25% by weight, 5% to 30% by weight, 5% to 35% by weight, 5% to 40% by weight, 5% to 45% by weight, 5% to 50% by weight, 5% to 60% by weight, 5% to 70% by weight, 5% to 80% by weight, 10% to 15% by weight, 10% to 20% by weight, 10% to 30% by weight, 10% to 40% by weight, 10% to 50% by weight, 10% to 60% by weight, 10% to 70% by weight, 10% to 80% by weight, 20% to 30% by weight, 20% to 40% by weight, 20% to 50% by weight, 20% to 60% by weight, 20% to 70% by weight, 20% to 80% by weight, 30% to 40% by weight, 30% to 50% by weight, 30% to 40% by weight % to 60 wt %, 30 wt % to 70 wt %, 30 wt % to 80 wt %, 40 wt % to 50 wt %, 40 wt % to 60 wt %, 40 wt % to 70 wt %, 40 wt % to 80 wt %, 50 wt % to 60 wt %, 50 wt % to 70 wt %, 50 wt % to 80 wt %, 60 wt % to 70 wt %, 60 wt % to 80 wt %, or 70 wt % to 80 wt %).

[0181] In some embodiments, when present, the internal sizing agent can be present in the slurry at a concentration of at least 0.03% by weight (e.g., at least 0.1%, at least 0.5%, at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, or at least 80% by weight) of the fiber matrix. In some embodiments, the internal sizing agent can be present in the slurry at a concentration of 90% by weight or less (e.g., 80% by weight or less, 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less) of the fiber matrix.

[0182] The internal sizing agent can be present in the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the internal sizing agent can be present in the slurry at a concentration of 0.03% to 90% by weight (e.g., 0.03% to 90% by weight, 0.03% to 80% by weight, 0.03% to 70% by weight, 0.03% to 60% by weight, 0.03% to 50% by weight, 0.03% to 40% by weight, 0.03% to 30% by weight, 0.03% to 20% by weight, 0.03% to 10% by weight, 0.03% to 5% by weight, 0.03% to 1% by weight, 1% to 90% by weight, 1% to 80 wt%, 1 wt% to 70 wt%, 1 wt% to 60 wt%, 1 wt% to 50 wt%, 1 wt% to 40 wt%, 1 wt% to 30 wt%, 1 wt% to 20 wt%, 1 wt% to 10 wt%, 1 wt% to 5 wt%, 5 wt% to 90 wt%, 5 wt% to 80 wt%, 5 wt% to 70 wt%, 5 wt% to 60 wt%, 5 wt% to 50 wt%, 5 wt% to 40 wt%, 5 wt% to 30 wt%, 5 wt% to 20 wt%, 5 wt% to 10 wt%, 10 wt% to 90 wt%, 10 wt% to 8 0 wt%, 10 wt% to 70 wt%, 10 wt% to 60 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, 20 wt% to 90 wt%, 20 wt% to 80 wt%, 20 wt% to 70 wt%, 20 wt% to 60 wt%, 20 wt% to 50 wt%, 20 wt% to 40 wt%, 20 wt% to 30 wt%, 30 wt% to 90 wt%, 30 wt% to 80 wt%, 30 wt% to 70 wt%, 30 wt% to 60 wt%, 30 % to 80 wt %, 40 wt % to 70 wt %, 40 wt % to 60 wt %, 40 wt % to 50 wt %, 50 wt % to 90 wt %, 50 wt % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, or 80 wt % to 90 wt %).

[0183] In some embodiments, the method does not include adding fluorocarbons or non-compostable synthetic polymers; or adding oil and grease resistant coatings.

[0184] In some embodiments, the fibrous matrix prepared by the methods described herein is a fibrous matrix described herein.

[0185] Products

[0186] Described herein are articles made using the fibrous matrices described herein and the methods described herein. Also described herein are articles comprising a fibrous matrix comprising pulped fibers and a polysaccharide distributed within the fibrous matrix.

[0187] The article may include a food container such as a box, cup, clamshell, plate, bowl, tray, carton, envelope, sack, bag, pouch, liner, divider, wrapper, film, sheet, or cushioning material.

[0188] Also described herein is a method of making an article, which may include blending pulped fibers, polysaccharides, and optionally fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0189] In some embodiments, a method of making an article may include blending pulped fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0190] In some embodiments, a method of making an article may include blending pulped fibers, polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof with water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0191] In some embodiments, a method of making an article may include blending pulped fibers, polysaccharide, and acid and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0192] In some embodiments, a method of making an article may include blending pulped fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, an acid, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0193] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0194] In some embodiments, blending may include adding the polysaccharide in the form of microparticles or insoluble particles.

[0195] In some embodiments, a method of making an article may include blending pulped fibers, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0196] In some embodiments, a method of making an article may include blending pulped fibers, cationic polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0197] In some embodiments, a method of making an article may include blending pulped fibers, anionic polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0198] In some embodiments, a method of making an article may include blending pulped fibers, non-ionizable polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0199] In some embodiments, the method may further include blending an internal sizing agent, filler, or any combination thereof with pulping fibers, polysaccharides, fatty acids or salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, and water to produce a slurry.

[0200] In some embodiments, the method may further include blending the filler material with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry. In some embodiments, the method may further include blending its internal sizing agent with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry. In some embodiments, the method may further include blending its internal sizing agent and filler with the pulping fibers, polysaccharides, fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof, and water to produce a slurry.

[0201] In some embodiments, a method of making an article may include blending pulped fibers; polysaccharide; and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0202] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0203] In some embodiments, blending may include adding the polysaccharide in the form of microparticles or insoluble particles.

[0204] In some embodiments, a method of making an article may include blending pulped fibers, non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0205] In some embodiments, a method of making an article may include blending pulped fibers, a cationic polysaccharide, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0206] In some embodiments, a method of making an article may include blending pulped fibers, anionic polysaccharides, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0207] In some embodiments, a method of making an article may include blending pulped fibers, a non-ionizable polysaccharide, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0208] In some embodiments, the method may further include blending a fatty acid or its salt, ester, amide, derivative, or any combination thereof, an internal sizing agent, a filler, an acid, or any combination thereof with the pulping fibers, water, and a polysaccharide to produce a slurry.

[0209] In some embodiments, the method may further include blending a filler with the pulping fibers, water, and a polysaccharide to produce a slurry. In some embodiments, the method may further include blending a fatty acid or its salt, ester, amide, derivative, or any combination thereof, an internal sizing agent, and a filler with the pulping fibers, polysaccharide, and water to produce a slurry. In some embodiments, the method may further include blending a fatty acid or its salt, ester, amide, derivative, or any combination thereof, and a filler with the pulping fibers, water, and a polysaccharide to produce a slurry. In some embodiments, the method may further include blending a fatty acid or its salt, ester, amide, derivative, or any combination thereof, and an internal sizing agent with the pulping fibers, water, and a polysaccharide to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent and a filler with the pulping fibers, water, and a polysaccharide to produce a slurry.

[0210] Also described herein is a method of making an article, the method comprising blending pulped fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and compressing and heating the wet mat to remove water, thereby forming the article.

[0211] In some embodiments, the method may further include blending an internal sizing agent, a filler, a polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent and a filler with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a polysaccharide and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the filler, polysaccharide, and surfactant with the pulping fibers, water, and the fatty acid or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0212] In some embodiments, the method may further include blending the acid and filler with the fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, internal sizing agent, filler, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, internal sizing agent and filler with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry. In some embodiments, the method may further include blending the acid, filler, polysaccharide and surfactant with the pulping fiber, water and fatty acid or its salt, ester, amide, derivative or any combination thereof to produce a slurry.

[0213] In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, anionic polysaccharides, or any combination thereof. In some embodiments, the polysaccharide may include non-ionizable polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides. In some embodiments, the polysaccharide may include anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides, cationic polysaccharides, and anionic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and cationic polysaccharides. In some embodiments, the polysaccharide may include non-ionizable polysaccharides and anionic polysaccharides. In some embodiments, the polysaccharide may include cationic polysaccharides and anionic polysaccharides.

[0214] In some embodiments, blending may include adding the polysaccharide in the form of microparticles or insoluble particles.

[0215] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0216] In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, a surfactant, an acid, or any combination thereof with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method can further include blending a filler, a nonionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof, and a surfactant with the pulping fibers, water, and a fatty acid or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0217] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a cationic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0218] In some embodiments, the method may further include blending an internal sizing agent, a filler, a cationic polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a cationic polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a cationic polysaccharide and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler, a cationic polysaccharide, and a surfactant with pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0219] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, an anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, an anionic polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or its salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0220] In some embodiments, the method may further include blending an internal sizing agent, filler, anionic polysaccharide, surfactant, acid, or any combination thereof with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, filler, anionic polysaccharide, and surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending anionic polysaccharides and surfactants with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending fillers, anionic polysaccharides, and surfactants with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry.

[0221] In some embodiments, the method may further include blending an acid, an internal sizing agent, a filler, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an acid, a filler, a non-ionizable polysaccharide, and a surfactant with the pulping fibers, water, and a fatty acid, or a salt, ester, amide, derivative, or any combination thereof to produce a slurry.

[0222] In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, a surfactant, an acid, or any combination thereof with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending an internal sizing agent, a filler, a non-ionizable polysaccharide, and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a non-ionizable polysaccharide and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry. In some embodiments, the method may further include blending a filler, a non-ionizable polysaccharide, and a surfactant with pulping fibers, water, and fatty acids, or salts, esters, amides, derivatives, or any combination thereof to produce a slurry.

[0223] In some embodiments, the acid can be present in the slurry at a concentration of at least 0.1 wt % (e.g., at least 1 wt %, at least 5 wt %, at least 10 wt %, at least 20 wt %, at least 30 wt %, at least 50 wt %, at least 60 wt %, at least 70 wt %, at least 80 wt %, or at least 90 wt %) of the polysaccharide.

[0224] In some embodiments, the acid can be present in the slurry at a concentration of 100 wt % or less (e.g., 90 wt % or less, 80 wt % or less, 70 wt % or less, 60 wt % or less, 50 wt % or less, 40 wt % or less, 30 wt % or less, 20 wt % or less, 10 wt % or less, 5 wt % or less, 1 wt % or less, or 0.5 wt % or less) based on the polysaccharide.

[0225] The acid can be present in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the acid can be present in a concentration ranging from 0.1% to 100% by weight (e.g., 0.1% to 90%, 0.1% to 80%, 0.1% to 70%, 0.1% to 60%, 0.1% to 50%, 0.1% to 40%, 0.1% to 30%, 0.1% to 20%, 0.1% to 10%, 0.1% to 5%, 0.1% to 100%, 1% to 90%, 1% to 80%, 1% to 100% by weight) of the polysaccharide. % to 70 wt %, 1 wt % to 60 wt %, 1 wt % to 50 wt %, 1 wt % to 40 wt %, 1 wt % to 30 wt %, 1 wt % to 20 wt %, 1 wt % to 10 wt %, 1 wt % to 5 wt %, 10 wt % to 100 wt %, 10 wt % to 90 wt %, 10 wt % to 80 wt %, 10 wt % to 70 wt %, 10 wt % to 60 wt %, 10 wt % to 50 wt %, 10 wt % to 40 wt %, 10 wt % to 30 wt %, 10 wt % to 20 wt %, 20 wt % to 100 wt %, 20 wt % to 90 %, 20% to 80% by weight, 20% to 70% by weight, 20% to 60% by weight, 20% to 50% by weight, 20% to 40% by weight, 20% to 30% by weight, 30% to 100% by weight, 30% to 90% by weight, 30% to 80% by weight, 30% to 70% by weight, 30% to 60% by weight, 30% to 50% by weight, 30% to 40% by weight, 40% to 100% by weight, 40% to 90% by weight, 40% to 80% by weight, 40% to 70% by weight, 40% to 50% by weight, % to 60 wt %, 40 wt % to 50 wt %, 50 wt % to 100 wt %, 50 wt % to 90 wt %, 50 wt % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 70 wt % to 100 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, 60 wt % to 100 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 80 wt % to 100 wt %, 80 wt % to 90 wt %, or 90 wt % to 100 wt %).

[0226] In some embodiments, the polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0227] The polysaccharide can be added to the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous substrate.

[0228] In some embodiments, the non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof may be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof may be present in the slurry at a concentration of 40% by weight or less (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0229] The non-ionizable polysaccharide, cationic polysaccharide, anionic polysaccharide, or any combination thereof can be added to the slurry in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the polysaccharide can be added in a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0230] In some embodiments, the cationic polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the cationic polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0231] The cationic polysaccharide can be added to the slurry at a concentration ranging from any one of the minimum values ​​described above to any one of the maximum values ​​described above. For example, in some embodiments, the cationic polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous substrate.

[0232] In some embodiments, the anionic polysaccharide can be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the anionic polysaccharide can be present in the slurry at a concentration of 40% or less by weight (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0233] The anionic polysaccharide can be added to the slurry in a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the anionic polysaccharide can be added in a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0234] In some embodiments, the non-ionizable polysaccharide may be present in the slurry at a concentration of at least 1% by weight (e.g., at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, or at least 35% by weight) of the fibrous matrix. In some embodiments, the non-ionizable polysaccharide may be present in the slurry at a concentration of 40% by weight or less (e.g., 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, or 5% or less) of the fibrous matrix.

[0235] The non-ionizable polysaccharide can be added to the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the non-ionizable polysaccharide can be added at a concentration of 1% to 40% by weight (e.g., 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, 1% to 30%, 5% to 40%, 5% to 30%, 5% to 20%, 5% to 15%, 5% to 10%, 10% to 40%, 10% to 30%, 10% to 20%, 10% to 15%, 20% to 30%, 20% to 40%, or 30% to 40% by weight) of the fibrous matrix.

[0236] In some embodiments, when present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof, can be present in the slurry at a concentration of at least 0.1% by weight (e.g., at least 0.5%, at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 60%, or at least 70% by weight) of the fibrous substrate. In some embodiments, when present, the fatty acids or their salts, esters, amides, derivatives, or any combination thereof, may be present in the slurry at a concentration of 80% or less by weight (e.g., 70% or less, 60% or less, 50% or less, 45% or less, 40% or less, 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 5% or less, 1% or less, or 0.5% or less by weight) of the fibrous matrix.

[0237] When present, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the fatty acid or its salt, ester, amide, derivative, or any combination thereof can be present in the slurry at a concentration ranging from 0.1% to 80% by weight (e.g., 0.1% to 1%, 0.1% to 5%, 0.1% to 10%, 0.1% to 15%, 0.1% to 20%, 0.1% to 25%, 0.1% to 30%, 0.1% to 35%, 0.1% to 40%, 0.1% to 45%, 0.1% to 50% by weight) of the fibrous substrate. %, 0.1 wt % to 60 wt %, 0.1 wt % to 70 wt %, 0.5 wt % to 1 wt %, 0.5 wt % to 5 wt %, 0.5 wt % to 10 wt %, 0.5 wt % to 15 wt %, 0.5 wt % to 20 wt %, 0.5 wt % to 25 wt %, 0.5 wt % to 30 wt %, 0.5 wt % to 35 wt %, 0.5 wt % to 40 wt %, 0.5 wt % to 45 wt %, 0.5 wt % to 50 wt %, 0.5 wt % to 60 wt %, 0.5 wt % to 70 wt %, 0.5% to 80% by weight, 1% to 5% by weight, 1% to 10% by weight, 1% to 15% by weight, 1% to 20% by weight, 1% to 25% by weight, 1% to 30% by weight, 1% to 35% by weight, 1% to 40% by weight, 1% to 45% by weight, 1% to 50% by weight, 1% to 60% by weight, 1% to 70% by weight, 1% to 80% by weight, 5% to 10% by weight, %, 5% to 15% by weight, 5% to 20% by weight, 5% to 25% by weight, 5% to 30% by weight, 5% to 35% by weight, 5% to 40% by weight, 5% to 45% by weight, 5% to 50% by weight, 5% to 60% by weight, 5% to 70% by weight, 5% to 80% by weight, 10% to 15% by weight, 10% to 20% by weight, 10% to 30% by weight, 10% to 40% by weight, 10% to 50% by weight, 10% to 60% by weight, 10% to 70% by weight, 10% to 80% by weight, 20% to 30% by weight, 20% to 40% by weight, 20% to 50% by weight, 20% to 60% by weight, 20% to 70% by weight, 20% to 80% by weight, 30% to 40% by weight, 30% to 50% by weight, 30% to 40% by weight % to 60 wt %, 30 wt % to 70 wt %, 30 wt % to 80 wt %, 40 wt % to 50 wt %, 40 wt % to 60 wt %, 40 wt % to 70 wt %, 40 wt % to 80 wt %, 50 wt % to 60 wt %, 50 wt % to 70 wt %, 50 wt % to 80 wt %, 60 wt % to 70 wt %, 60 wt % to 80 wt %, or 70 wt % to 80 wt %).

[0238] In some embodiments, when present, the internal sizing agent can be present in the slurry at a concentration of at least 0.03% by weight (e.g., at least 0.1%, at least 0.5%, at least 1%, at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, or at least 80% by weight) of the fiber matrix. In some embodiments, the internal sizing agent can be present in the slurry at a concentration of 90% by weight or less (e.g., 80% by weight or less, 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, 20% by weight or less, 10% by weight or less, 5% by weight or less, 1% by weight or less, 0.5% by weight or less, or 0.1% by weight or less) of the slurry.

[0239] The internal sizing agent can be present in the slurry at a concentration ranging from any of the minimum values ​​described above to any of the maximum values ​​described above. For example, in some embodiments, the internal sizing agent can be present in the slurry at a concentration of 0.03% to 90% by weight (e.g., 0.03% to 90% by weight, 0.03% to 80% by weight, 0.03% to 70% by weight, 0.03% to 60% by weight, 0.03% to 50% by weight, 0.03% to 40% by weight, 0.03% to 30% by weight, 0.03% to 20% by weight, 0.03% to 10% by weight, 0.03% to 5% by weight, 0.03% to 1% by weight, 1% to 90% by weight, 1% to 80 wt%, 1 wt% to 70 wt%, 1 wt% to 60 wt%, 1 wt% to 50 wt%, 1 wt% to 40 wt%, 1 wt% to 30 wt%, 1 wt% to 20 wt%, 1 wt% to 10 wt%, 1 wt% to 5 wt%, 5 wt% to 90 wt%, 5 wt% to 80 wt%, 5 wt% to 70 wt%, 5 wt% to 60 wt%, 5 wt% to 50 wt%, 5 wt% to 40 wt%, 5 wt% to 30 wt%, 5 wt% to 20 wt%, 5 wt% to 10 wt%, 10 wt% to 90 wt%, 10 wt% to 8 0 wt%, 10 wt% to 70 wt%, 10 wt% to 60 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, 20 wt% to 90 wt%, 20 wt% to 80 wt%, 20 wt% to 70 wt%, 20 wt% to 60 wt%, 20 wt% to 50 wt%, 20 wt% to 40 wt%, 20 wt% to 30 wt%, 30 wt% to 90 wt%, 30 wt% to 80 wt%, 30 wt% to 70 wt%, 30 wt% to 60 wt%, 30 % to 80 wt %, 40 wt % to 70 wt %, 40 wt % to 60 wt %, 40 wt % to 50 wt %, 50 wt % to 90 wt %, 50 wt % to 80 wt %, 50 wt % to 70 wt %, 50 wt % to 60 wt %, 60 wt % to 90 wt %, 60 wt % to 80 wt %, 60 wt % to 70 wt %, 70 wt % to 90 wt %, 70 wt % to 80 wt %, or 80 wt % to 90 wt %).

[0240] In some embodiments, the method does not include adding fluorocarbons or non-compostable synthetic polymers; or adding oil and grease resistant coatings.

[0241] In some embodiments, the article can be oil-resistant and water-resistant. In some embodiments, the article can be hot water-resistant, cold water-resistant, hot oil-resistant, cold oil-resistant, or any combination thereof.

[0242] Reference will now be made in detail to specific aspects of the disclosed materials, compounds, compositions, articles and methods, examples of which are illustrated in the accompanying examples and figures.

[0243] According to the present disclosure, all compositions and methods disclosed and claimed herein can be prepared and performed without excessive experimentation. Although the compositions and methods of the present disclosure have been described in conjunction with preferred embodiments, it is obvious to those skilled in the art that the steps or sequence of steps in the compositions and methods and the methods described herein can be changed without departing from the concept, spirit and scope of the present disclosure. More specifically, it will be apparent that certain chemically related agents can replace the agents described herein while achieving the same or similar results. It will be apparent to those skilled in the art that all such similar substitutions and modifications are deemed to be within the spirit, scope and concept of the present disclosure as defined by the appended claims.

[0244] Exemplary embodiments

[0245] Embodiment 1: A fibrous matrix comprising pulping fibers, one or more polysaccharides, and fatty acids or their salts, esters, amides, derivatives, or any combination thereof, acids, or any combination thereof, distributed within the fibrous matrix.

[0246] Embodiment 2: The fibrous matrix according to any one of embodiments 1-2, wherein the polysaccharide comprises a cationic polysaccharide comprising chitin, chitosan, partially deacetylated chitin, cationic starch, cationic cellulose, cationic dextran, cationic guar gum, or any combination thereof.

[0247] Embodiment 3: The fibrous matrix according to any one of embodiments 1-2, wherein the polysaccharide comprises an anionic polysaccharide comprising heparin, hyaluronic acid, carrageenan, alginic acid, alginate, chondroitin sulfate, or any combination thereof.

[0248] Embodiment 4: The fibrous matrix according to any one of embodiments 1-2, wherein the polysaccharide comprises a non-ionizable polysaccharide selected from the group consisting of starch, cellulose, hemicellulose, dextran, guar gum, tara gum, glucomannan, curdlan, or any combination thereof.

[0249] Embodiment 5: The fibrous matrix according to any one of Embodiments 1-4, wherein the polysaccharide is present in a concentration of 1% to 20% by weight of the fibrous matrix.

[0250] Embodiment 6: The fibrous matrix according to any one of embodiments 1 to 5, comprising fatty acids or their salts, esters, amides, derivatives or any combination thereof.

[0251] Embodiment 7: The fibrous matrix according to any one of embodiments 1-6, wherein the fatty acid is selected from oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenolenic acid, triacontanic acid, and any combination thereof.

[0252] Embodiment 8: The fibrous matrix according to embodiment 7, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

[0253] Embodiment 9: The fibrous matrix according to embodiment 6, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

[0254] Embodiment 10: The fibrous matrix of Embodiment 6, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof comprises zinc stearate, magnesium stearate, aluminum stearate, stearic acid, or any combination thereof.

[0255] Embodiment 11: The fibrous substrate of Embodiment 6, wherein the fatty acid amide comprises stearamide, ethylene bisstearamide, oleamide, ethylene bisoleamide, or any combination thereof.

[0256] Embodiment 12: The fibrous matrix according to any one of Embodiments 6-11, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof is present in a concentration of 0.1% to 50% by weight of the fibrous matrix.

[0257] Embodiment 13: The fibrous matrix of any one of Embodiments 1-12, comprising an acid.

[0258] Embodiment 14: The fibrous matrix of embodiments 1-13, wherein the acid comprises hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, citric acid, oxalic acid, uric acid, tartaric acid, or any combination thereof.

[0259] Embodiment 15: The fibrous substrate of any one of Embodiments 1-14, further comprising an internal sizing agent.

[0260] Embodiment 16: The fibrous substrate of embodiment 15, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, alkenyl succinic anhydride, rosin, wax, stearic anhydride or other fatty acid anhydrides.

[0261] Embodiment 17: The fibrous substrate of Embodiment 18, wherein the internal sizing agent is an alkyl ketene dimer.

[0262] Embodiment 18: The fibrous matrix of any of Embodiments 15-17, wherein the internal sizing agent is present at 0.03% to 90% by weight of the fibrous matrix.

[0263] Embodiment 19: The fibrous matrix of any one of Embodiments 1-17, further comprising a filler material.

[0264] Embodiment 20: The fibrous substrate according to embodiment 19, wherein the filler material comprises minerals, lignocellulosic particles or any compostable material (biodegradable or inorganic) that can be used as a filler or any combination thereof.

[0265] Embodiment 21: The fibrous substrate of any of Embodiments 1-20, wherein the pulping fibers comprise cellulosic fibers.

[0266] Embodiment 22: The fibrous matrix of any one of Embodiments 1-21, comprising pulping fibers, acetic acid, and a cationic polysaccharide distributed within the fibrous matrix.

[0267] Embodiment 23: The fibrous matrix of any one of Embodiments 1-21, comprising pulping fibers, acetic acid, zinc stearate, and a cationic polysaccharide distributed within the fibrous matrix.

[0268] Embodiment 24: A fibrous matrix comprising pulping fibers, a polysaccharide, an acid, and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof, distributed within the fibrous matrix.

[0269] The total weight percentage of all polysaccharides and all fatty acids or their salts, esters, amides, derivatives or any combination thereof present in the fiber matrix is ​​greater than 5% to 55%.

[0270] Embodiment 25: A fibrous matrix comprising pulping fibers, a cationic polysaccharide, an acid, and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof, distributed within the fibrous matrix.

[0271] Embodiment 26: The fibrous substrate of any one of Embodiments 23-25, further comprising an internal sizing agent, a filler, or any combination thereof.

[0272] Embodiment 27: A fibrous matrix comprising pulped fibers and a fatty acid or a salt, ester, amide, derivative thereof, or any combination thereof, distributed within the fibrous matrix.

[0273] Embodiment 28: The fibrous matrix of Embodiment 27, further comprising a polysaccharide, a surfactant, an internal sizing agent, a filler, an acid, or any combination thereof.

[0274] Embodiment 29: A fibrous matrix comprising pulped fibers; a polysaccharide, a fatty acid, a salt, an ester, an amide, a derivative thereof, or any combination thereof; and distributed within the fibrous matrix.

[0275] Embodiment 30: The fibrous matrix of any one of Embodiments 24-29, wherein the polysaccharide comprises a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof.

[0276] Embodiment 31: A fibrous matrix according to any one of embodiments 23-30, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof is selected from oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenolenic acid, triacontanic acid and any combination thereof.

[0277] Embodiment 32: The fibrous matrix according to embodiments 23-31, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

[0278] Embodiment 33: The fibrous matrix of embodiments 23-31, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

[0279] Embodiment 34: The fibrous matrix of any one of Embodiments 23-31, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof comprises zinc stearate, magnesium stearate, stearic acid, an aluminum salt of the fatty acid, or any combination thereof.

[0280] Embodiment 35: The fibrous matrix of any one of Embodiments 23-34, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof is present in a concentration of 0.1% to 50% by weight of the fibrous matrix.

[0281] Embodiment 36: The fibrous matrix of any one of Embodiments 27-35, comprising pulping fibers and zinc stearate distributed within the fibrous matrix.

[0282] Embodiment 37: The fibrous substrate of any of Embodiments 29-36, further comprising a surfactant, an internal sizing agent, a filler, an acid, or any combination thereof.

[0283] Embodiment 38: A fibrous matrix according to any one of Embodiments 26, 28 or 37, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, an alkenyl succinic anhydride, a rosin, a wax, stearic anhydride or other fatty acid anhydride.

[0284] Embodiment 39: The fibrous substrate of Embodiment 38, wherein the internal sizing agent is an alkyl ketene dimer.

[0285] Embodiment 40: The fibrous matrix of any of Embodiments 26, 28, or 37-39, wherein the internal sizing agent is present at 0.03% to 90% by weight of the fibrous matrix.

[0286] Embodiment 41: The fibrous matrix of any one of Embodiments 24-26, 28, or 37-40, wherein the acid comprises hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, citric acid, oxalic acid, uric acid, tartaric acid, or any combination thereof.

[0287] Embodiment 42: The fibrous matrix of any one of Embodiments 1-41, wherein the fibrous matrix is ​​water and oil resistant when compressed and heated.

[0288] Embodiment 43: A method for preparing a fibrous matrix, the method comprising:

[0289] blending pulping fibers, polysaccharide, and optionally fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or any combination thereof, and water to produce a slurry;

[0290] casting the slurry into a wet mat in the shape of a product; and

[0291] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0292] Embodiment 44: A method for preparing a fibrous matrix, the method comprising:

[0293] blending pulping fibers, polysaccharide, and fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or any combination thereof, and water to produce a slurry;

[0294] casting the slurry into a wet mat in the shape of a product; and

[0295] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0296] Embodiment 45: A method for preparing a fibrous matrix, the method comprising:

[0297] blending pulping fibers, polysaccharides, fatty acids or salts, esters, amides, derivatives thereof, or any combination thereof, and acid and water to produce a slurry;

[0298] casting the slurry into a wet mat in the shape of a product; and

[0299] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0300] Embodiment 46: The method of any one of Embodiments 43-45, further comprising blending an internal sizing agent, a filler, or any combination thereof to produce a slurry.

[0301] Embodiment 47: A method for preparing a fibrous matrix, the method comprising:

[0302] blending pulping fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry;

[0303] casting the slurry into a wet mat in the shape of a product; and

[0304] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0305] Embodiment 48: The method of Embodiment 47, further comprising blending an acid, a polysaccharide, an internal sizing agent, a filler, a surfactant, or any combination thereof with pulping fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry.

[0306] Embodiment 49: The method according to any one of Embodiments 43-48, wherein the polysaccharide comprises a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof.

[0307] Embodiment 50: A method according to any one of embodiments 43-49, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof is selected from oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenolenic acid, triacontanic acid and any combination thereof.

[0308] Embodiment 51: The method according to embodiments 43-50, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

[0309] Embodiment 52: The method according to embodiments 43-50, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

[0310] Embodiment 53: The method according to any one of Embodiments 43-50, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof comprises zinc stearate, magnesium stearate, aluminum stearate, stearic acid or any combination thereof.

[0311] Embodiment 54: The method according to any one of Embodiments 46 or 48, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, an alkenyl succinic anhydride, a rosin, a wax, a stearic anhydride or other fatty acid anhydrides.

[0312] Embodiment 55: The method of Embodiment 54, wherein the internal sizing agent is alkyl ketene dimer (AKD).

[0313] Embodiment 56: A method according to any one of embodiments 43-45 or 48-55, wherein the acid comprises hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, citric acid, oxalic acid, uric acid, tartaric acid, or any combination thereof.

[0314] Embodiment 57: The method of any one of Embodiments 43-45 or 48-56, wherein the acid is present in the slurry at a concentration of 0.1% to 100% by weight of the polysaccharide.

[0315] Embodiment 58: The method of any one of Embodiments 44-57, wherein the fibers comprise cellulose fibers.

[0316] Embodiment 59: The method of any one of Embodiments 44-58, wherein the blending comprises adding the polysaccharide in the form of microparticles or insoluble particles.

[0317] Embodiment 60: The method of any one of Embodiments 44-59, wherein the method does not comprise adding fluorocarbons or non-compostable synthetic polymers; or adding an oil- and grease-resistant coating.

[0318] Embodiment 61: An article comprising a fibrous matrix according to any one of Embodiments 1-43.

[0319] Embodiment 62: An article comprising a fibrous matrix comprising pulped fibers and a polysaccharide distributed within the fibrous matrix.

[0320] Embodiment 63: The article of embodiment 62, wherein the polysaccharide comprises a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof.

[0321] Embodiment 64: The article of any one of Embodiments 62-63, further comprising a fatty acid or its salt, ester, amide, derivative, or any combination thereof, an internal sizing agent, a filler, an acid, a surfactant, or any combination thereof, and pulping fibers, a polysaccharide, and water to produce a slurry.

[0322] Embodiment 65: The article according to any of embodiments 62-64, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof is selected from oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristoleic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenoleic acid, triacontanic acid and any combination thereof.

[0323] Embodiment 66: The article according to any one of embodiments 62-65, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

[0324] Embodiment 67: The article of any one of Embodiments 62-65, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

[0325] Embodiment 68: The fibrous matrix of any one of Embodiments 62-65, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof comprises zinc stearate, magnesium stearate, aluminum stearate, stearic acid, or any combination thereof.

[0326] Embodiment 69: The article of any one of Embodiments 62-68, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, alkenyl succinic anhydride, rosin, wax, stearic anhydride or other fatty acid anhydride.

[0327] Embodiment 70: The article of embodiment 69, wherein the internal sizing agent is alkyl ketene dimer (AKD).

[0328] Embodiment 71: The article of any one of Embodiments 62-70, wherein the acid comprises hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, or any combination thereof.

[0329] Embodiment 72: The article of any of Embodiments 62-71, wherein the fibers comprise cellulosic fibers.

[0330] Embodiment 73: The article of any one of Embodiments 61-72, wherein the article is a food container.

[0331] Embodiment 74: The article of embodiment 73, wherein the food container is a box, a cup, a clamshell, a plate, a bowl, a tray, a carton, an envelope, a sack, a bag, a pouch, a liner, a divider, a wrapper, a film, a sheet, or a cushioning material.

[0332] Embodiment 75: The article of any of Embodiments 61-74, wherein the article is hot water resistant and cold water resistant.

[0333] Embodiment 76: A method of making an article, the method comprising:

[0334] blending pulping fibers, polysaccharide, and optionally fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or any combination thereof, and water to produce a slurry;

[0335] casting the slurry into a wet mat in the shape of a product; and

[0336] The wet mat is compressed and heated to drive off the water, thereby forming the article.

[0337] Embodiment 77: A method of making an article, the method comprising:

[0338] blending pulping fibers, polysaccharide, and fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or any combination thereof, and water to produce a slurry;

[0339] casting the slurry into a wet mat in the shape of a product; and

[0340] The wet mat is compressed and heated to drive off the water, thereby forming the article.

[0341] Embodiment 78: A method of making an article, the method comprising:

[0342] blending pulping fibers, polysaccharides, fatty acids or salts, esters, amides, derivatives thereof, or any combination thereof, and acid and water to produce a slurry;

[0343] casting the slurry into a wet mat in the shape of a product; and

[0344] The wet mat is compressed and heated to drive off the water, thereby forming the article.

[0345] Embodiment 79: The method of any one of Embodiments 76-78, further comprising blending an internal sizing agent, a filler, or any combination thereof to produce a slurry.

[0346] Embodiment 80: A method for preparing a fibrous matrix, the method comprising:

[0347] blending pulping fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry;

[0348] casting the slurry into a wet mat in the shape of a product; and

[0349] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0350] Embodiment 81: The method of embodiment 80, further comprising blending an acid, a polysaccharide, an internal sizing agent, a filler, a surfactant, or any combination thereof with pulping fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry.

[0351] Embodiment 82: A method of making an article, the method comprising:

[0352] blending pulping fibers, polysaccharide, and water to produce a slurry;

[0353] casting the slurry into a wet mat in the shape of a product; and

[0354] The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

[0355] Embodiment 83: The method according to embodiment 82, further comprising an acid; a fatty acid or its salt, ester, amide, derivative or any combination thereof; an internal sizing agent, a filler, a surfactant; or any combination thereof.

[0356] Embodiment 84: The method of any one of Embodiments 76-83, wherein the polysaccharide comprises a non-ionizable polysaccharide, a cationic polysaccharide, an anionic polysaccharide, or any combination thereof.

[0357] Embodiment 85: A method according to any one of embodiments 76-84, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof is selected from oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenolenic acid, triacontanic acid and any combination thereof.

[0358] Embodiment 86: A method according to any one of embodiments 76-85, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

[0359] Embodiment 87: The method according to embodiments 76-85, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

[0360] Embodiment 88: The method of any one of Embodiments 76-86, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof comprises zinc stearate, magnesium stearate, stearic acid, aluminum stearate, or any combination thereof.

[0361] Embodiment 89: The method of embodiment 79, 81 or 83-88, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, alkenyl succinic anhydride, rosin, wax, stearic anhydride or other fatty acid anhydride.

[0362] Embodiment 90: A method according to Embodiment 74; wherein the internal sizing agent is alkyl ketene dimer (AKD).

[0363] Embodiment 91: The method of any one of Embodiments 76-90, wherein the acid comprises hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, or any combination thereof.

[0364] Embodiment 92: The method of any one of Embodiments 78-86, wherein the fibers comprise cellulose fibers.

[0365] Embodiment 93: The method of any one of Embodiments 76-92, wherein the blending comprises adding the polysaccharide in the form of microparticles or insoluble particles.

[0366] Embodiment 94: The method of any one of Embodiments 76-93, wherein the method does not comprise adding fluorocarbons or non-compostable synthetic polymers; or adding an oil- and grease-resistant coating.

[0367] Embodiment 95: The method of any one of Embodiments 76-94, wherein the article is oil and water resistant.

[0368] Embodiment 96: The method of any one of Embodiments 76-95, wherein the article is a food container.

[0369] Embodiment 97: The method according to Embodiment 96, wherein the food container is a box, a cup, a clamshell box, a plate, a bowl, a tray, a carton, an envelope, a large bag, a bag, a small bag, a liner, a partition, a wrapping paper, a film, a sheet or a cushioning material.

[0370] Examples of certain embodiments of the present disclosure are given below by way of non-limiting illustration.

[0371] Example

[0372] The following examples are presented to provide those skilled in the art with a complete disclosure and description of how to make and evaluate the compounds, compositions, articles, devices and / or methods claimed herein, and are intended to be purely illustrative of the present invention and are not intended to limit the scope to which the inventors regard their invention. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperatures, etc.), but some errors and deviations should be considered. Unless otherwise indicated, parts are parts by weight, temperatures are in ° C or at ambient temperature, and pressures are at or near atmospheric pressure.

[0373] Example 1: Preparation of an oil-resistant and water-resistant composite material comprising a polysaccharide and an acid.

[0374] Chitin / chitosan materials are heteropolysaccharides composed of N-acetylglucosamine and D-glucosamine. The solubility of chitin / chitosan materials in mild acetic acid depends on the amount of D-glucosamine and the distribution of D-glucosamine in the polysaccharide. Chitin subjected to a commercial thermochemical deacetylation process typically produces chitosan with a D-glucosamine content exceeding 85%, and which is soluble in mild acetic acid.

[0375] For acid-insoluble chitin, it was soaked in a 0.2% acetic acid solution for 18 hours. Then, a 1.5% chitin slurry was prepared by blending in a home blender for 30 minutes. The consistency of the resulting chitin slurry was the same as that of cream. The chitin slurry was mixed with 12g of fiber and water to obtain a 3% slurry. 2.4g of 15% AKD was added to the fiber / chitin slurry and blended for another 30 seconds. The slurry was diluted with water to make a 0.5% fiber / chitin slurry. The fiber / chitin slurry was filtered through 16-20 mesh to remove excess water by gravity filtration. The wet cake was further subjected to vacuum suction to remove more water. Finally, the fiber / chitin composite was hot pressed at 190°C, 0.4MPa for 1 minute. Three discs of 4-inch diameter molds were produced for each formulation. An aliquot of 0.5g-1g 90°C oil was poured on the surface of each sample, and the time required for oil penetration to be found at the bottom was recorded. For practical food packaging applications, the molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieved this level of oil resistance were recorded as "Excellent".

[0376] For acid-soluble chitosan, it was dissolved in 1% acetic acid to produce a 1% chitosan solution. 1% NaOH was gradually added to the chitosan solution while stirring until pH 9 was reached. The resulting chitosan gel was filtered through a 16-20 mesh filter. The gel was blended with 12g of pulped fiber and water in a home blender to obtain a 3% pulp slurry. 2.4g of 15% AKD was added to the fiber / chitosan slurry and blended for another 30 seconds. The slurry was diluted with water to make a 0.5% fiber / chitosan slurry. The fiber / chitosan slurry was filtered through a 16-20 mesh to remove excess water by gravity filtration. The wet cake was further subjected to vacuum suction to remove more water. Finally, the fiber / chitosan composite was hot pressed at 190°C, 0.4MPa for 1 minute. Three discs of 4-inch diameter molds were produced for each formulation. An aliquot of 0.5g-1g of 90°C oil was poured on the surface of each sample, and the time required for oil penetration to be found at the bottom was recorded. For practical food packaging applications, molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieved this level of oil resistance were recorded as "excellent".

[0377] Table 1. Formulations used to make fiber composites using cationic polysaccharides and acetic acid and oil testing results

[0378]

[0379]

[0380] When the amount of chitin / chitosan material in the molded pulp product is reduced from 15% to 10%, the oil resistance of the molded pulp is significantly reduced. It is not necessary to increase the amount of chitosan in the product, and chitosan can be mixed with other water-soluble polysaccharides to achieve the desired oil resistance, as shown in Table 2.

[0381] In this example, anionic polysaccharides (λ-carrageenan) and neutral polysaccharides (guar gum). A predetermined amount of 1% chitosan and 1% λ-carrageenan solution (Table 2) were mixed, and the mixture was left to stand for 18 hours to complete the reaction. The resulting gel was filtered through a 16-20 mesh screen. The gel was blended with 12g of pulping fiber and water in a household blender to obtain a 3% pulp slurry. 2.4g of 15% AKD was added to the fiber / chitosan / λ-carrageenan slurry and blended for another 30 seconds. The slurry was diluted with water to make a 0.5% fiber / chitosan slurry. The fiber / chitosan / λ-carrageenan slurry was filtered through a 16-20 mesh to remove excess water by gravity filtration. The wet cake was further subjected to vacuum suction to remove more water. Finally, the fiber / chitosan / λ-carrageenan composite was hot pressed at 190°C, 0.4MPa for 1 minute. Three 4-inch diameter mold discs were produced for each formulation. An aliquot of 0.5g-1g of 90°C oil was poured on the surface of each sample, and the time required for oil penetration to be found at the bottom was recorded. For practical food packaging applications, molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieved this level of oil resistance were recorded as "excellent".

[0382] The predetermined amount of 1% chitosan and 1% guar gum solution (Table 2) was mixed and precipitated with 1% NaOH while stirring until pH 11 was reached. The resulting gel was filtered through a 16-20 mesh screen. The gel was blended with 12g pulping fiber and water in a household blender to obtain a 3% pulp slurry. 2.4g of 15% AKD was added to the fiber / chitosan / guar gum slurry and blended for another 30 seconds. The slurry was diluted with water to make a 0.5% fiber / chitosan / guar gum slurry. The fiber / chitosan / guar gum slurry was filtered through a 16-20 mesh to remove excess water by gravity filtration. The wet cake was further subjected to vacuum suction to remove more water. Finally, the fiber / chitosan / guar gum composite was hot pressed for 3 minutes at 150°C and 0.2MPa. Each formulation produced three 4-inch diameter mold discs. An aliquot of 0.5g-1g of 90°C oil was poured on the surface of each sample, and the time required for oil penetration to be found at the bottom was recorded. For practical food packaging applications, molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieved this level of oil resistance were recorded as "excellent".

[0383] Table 2. Formulations used to make fiber composites using polysaccharides and acetic acid and oil testing results

[0384] sample Comparison 10CTS CTS / CGN CTS / GG Bagasse fiber(g) 12 12 12 12 Water(g) 2,400 2,400 2,400 2,400 Chitosan(g) 0 1.2 0.8 1.2 λ-Carrageenan(g) 0 0 1.6 0 Guar gum(g) 0 0 0 1.2 Final weight (g) 11.23 12.27 12.40 12.12 Weight of polysaccharide in final product (g) 0 1.04 1.17 0.89 Percentage of polysaccharides in the final product (%) 0 8.5 9.4 7.3 Oil resistance (90℃ oil test) <5 minutes About 30 minutes Excellent Excellent

[0385] 3% pulp slurry is prepared by mixing 12g of pulping fiber and water in a household blender. Starch slurry is prepared by blending a predetermined amount of starch powder (as shown in Table 3 below) in 30g of 0.1% acetic acid solution for 30 seconds and waiting for 5 minutes before adding to the pulp slurry. The pulp slurry is blended again for 30 seconds. 2.4g of 15% AKD is added to the fiber / cationic starch slurry and blended for another 30 seconds. The slurry is diluted with water to make a 0.5% fiber / starch slurry. The fiber / starch slurry is filtered through 16-20 meshes to remove excess water by gravity filtration. The wet cake is further subjected to vacuum suction to remove more water. Finally, the fiber / starch composite is hot pressed at 190°C, 0.4MPa for 1 minute. Three 4-inch diameter discs are produced for each formulation. An aliquot of 0.5g-1g 90°C oil is poured on the surface of each sample, and the time required for oil penetration is recorded at the bottom. For practical food packaging applications, the molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieved this level of oil resistance were recorded as "Excellent".

[0386] Table 3. Formulations used to make fiber composites using starch and acetic acid and oil testing results

[0387] sample Comparison Corn starch Cationic starch Sweet potato starch Bagasse fiber(g) 12 12 12 12 Water(g) 2,400 2,400 2,400 2,400 Starch(g) 0 3.6 3.6 3.6 Final weight (g) 11.65 14.15 14.11 14.03 Weight of polysaccharide in final product (g) 0 2.5 2.46 2.38 Percentage of polysaccharides in the final product (%) 0 16.4 17.4 17.0 Oil resistance (90℃ oil test) <5 minutes Excellent Excellent Excellent

[0388] Depending on the weight and thickness of the molded pulp product, a final product containing more than 5% starch can provide the desired water and oil resistance properties. The results show that at lower starch concentrations, excellent oil resistance (90°C hot oil resistance for at least 2 hours) can be achieved by varying the weight and thickness of the final product.

[0389] Example 2: Preparation of oil-resistant and water-resistant composite materials comprising fatty acids or their salts, esters, amides, derivatives or any combination thereof

[0390] 3% fiber slurry is prepared by mixing 15g of fiber and water. The fiber comes from bagasse. The fiber / water mixture is blended for 30 seconds to disperse the fiber. Different concentrations (20% or 10%) of fatty acids or their salts, esters, amides, derivatives or any combination thereof (e.g., stearic acid, zinc stearate, magnesium stearate, calcium stearate or monostearyl citrate) are mixed with a dispersant and added to the fiber slurry. Cationic polysaccharides (e.g., chitosan, cationic starch or cationic guar gum) can be used as dispersants. In the following examples, 0.06% chitosan solution (Table 4) and 5% cationic starch slurry (Table 5) are used as dispersants. Stearate dispersion is added to the slurry and diluted with water to make a slurry of 0.5% fiber / fatty acid or its salts, esters, amides, derivatives or any combination thereof. The slurry of fiber / fatty acid or its salts, esters, amides, derivatives or any combination thereof is filtered through 16-20 mesh to remove excess water by gravity filtration, followed by vacuum suction. Finally, the slurry of fiber / fatty acid or its salt, ester, amide, derivative or any combination thereof was hot pressed at 190°C, 0.4 MPa for 1 minute. Three 4-inch diameter discs were produced for each formulation. An aliquot of 0.5g-1g 90°C oil was poured on the surface of each sample and the time required for oil penetration to be found at the bottom was recorded. For practical food packaging applications, molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieve this level of oil resistance are recorded as "excellent".

[0391] Table 4. Oil resistance of molded pulp products with stearate dispersion (chitosan as dispersant). Oil test was performed by dropping 90°C oil on the sample. Excellent means no penetration for at least 2 hours.

[0392] sample Comparison Zinc stearate Calcium stearate Magnesium Stearate Bagasse fiber(g) 15 15 15 15 Water(g) 3,000 3,000 3,000 3,000 Stearate(g) 0 3.0 3.0 3.0 Final weight (g) 14.33 15.90 16.81 16.28 Stearate weight (g) 0 1.57 2.48 1.95 Stearate(%) 0 9.9 14.8 12.0 Oil resistance <5 minutes Excellent Excellent Excellent

[0393] Table 5. Oil resistance of molded pulp products with stearate dispersion (cationic starch as dispersant) and acid. The oil test was performed by dropping 90°C oil on the sample. Excellent means no penetration for at least 2 hours.

[0394]

[0395] The results show that the composition including stearate at a concentration of 10% or 20% achieves excellent oil resistance (90°C hot oil resistance for at least 2 hours). Alternatively, similar oil resistance can be achieved without the use of acetic acid. (Table 6) In this experiment, 1.2g of corn starch and 1.2g of magnesium stearate were added sequentially to a 3% pulping fiber slurry. The fiber / starch / magnesium stearate slurry was then filtered through a 16-20 mesh to remove excess water by gravity filtration, followed by vacuum suction. The resulting wet fiber / starch / magnesium stearate composite was hot pressed at 190°C, 0.4MPa for 1 minute. This formulation produced three 4-inch diameter discs. An aliquot of 0.5g-1g 90°C oil was poured on the surface of each sample, and the time required for oil penetration to be found at the bottom was recorded. For actual food packaging applications, molded pulp products need to be resistant to 90°C oil for at least 2 hours. Therefore, formulations that achieve this level of oil resistance are recorded as "excellent".

[0396] Table 6. Oil resistance of molded pulp products with magnesium stearate and corn starch. Oil test was performed by dropping 90°C oil on the sample. Excellent means no penetration for at least 2 hours.

[0397] sample Comparison CRN / MgSt Bagasse fiber(g) 15 15 Water(g) 3,000 3,000 Starch(g) 0 1.2 MgSt(g) 0 1.2 Final weight (g) 14.40 16.97 Additive weight (g) 0 2.57 additive(%) 0 15.1 Oil resistance (90℃ oil test) <5 minutes Excellent

[0398] The scope of the compositions and methods of the appended claims is not limited by the specific compositions and methods described herein, which are intended only to illustrate several aspects of the claims, and any functionally equivalent compositions and methods are intended to fall within the scope of the claims. In addition to the compositions and methods shown and described herein, various modifications of the compositions and methods are intended to fall within the scope of the appended claims. In addition, although only certain representative compositions and method steps disclosed herein are specifically described, other combinations of composition and method steps are also intended to fall within the scope of the appended claims, even if not specifically described. Therefore, combinations of steps, elements, components, or ingredients may be explicitly mentioned herein; however, other combinations of steps, elements, components, and ingredients are included even if not explicitly stated.

[0399] The scope of the compositions and methods of the appended claims is not limited by the specific compositions and methods described herein, which are intended only to illustrate several aspects of the claims, and any functionally equivalent compositions and methods are intended to fall within the scope of the claims. In addition to the compositions and methods shown and described herein, various modifications of the compositions and methods are intended to fall within the scope of the appended claims. In addition, although only certain representative compositions and method steps disclosed herein are specifically described, other combinations of composition and method steps are also intended to fall within the scope of the appended claims, even if not specifically described. Therefore, combinations of steps, elements, components, or ingredients may be explicitly mentioned herein; however, other combinations of steps, elements, components, and ingredients are included even if not explicitly stated.

Claims

1. A fiber matrix, comprising: Pulping fibers, one or more polysaccharides, and Fatty acids or their salts, esters, amides, derivatives or any combination thereof, acids or any combination thereof distributed within the fiber matrix.

2. The fibrous matrix of claim 1, wherein the polysaccharide comprises a cationic polysaccharide selected from the group consisting of chitin, chitosan, partially deacetylated chitin, cationic starch, cationic cellulose, cationic dextran, cationic guar gum, and any combination thereof.

3. The fibrous matrix of claim 1, wherein the polysaccharide comprises an anionic polysaccharide selected from the group consisting of heparin, hyaluronic acid, carrageenan, alginic acid, alginate, chondroitin sulfate, or any combination thereof.

4. The fibrous matrix of claim 1, wherein the polysaccharide comprises a non-ionizable polysaccharide selected from the group consisting of starch, cellulose, hemicellulose, dextran, guar gum, tera gum, glucomannan, curdlan, or any combination thereof.

5. The fibrous matrix of claim 1, wherein the polysaccharide is present at a concentration of 1% to 20% by weight of the fibrous matrix.

6. The fibrous substrate of claim 1, wherein the fatty acid or its salt, ester, amide, derivative or any combination thereof is present.

7. The fibrous matrix of claim 6, wherein the fatty acid is selected from the group consisting of oleic acid, caprylic acid, nonanoic acid, capric acid, lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, montanic acid, melissic acid, palmitoleic acid, myristoleic acid, linoleic acid, linolenic acid, petroselinic acid, vaccenic acid, gadoleic acid, cetyl oleic acid, erucic acid, shark acid, ximenolenic acid, triacontanic acid, and any combination thereof.

8. The fibrous matrix of claim 6, wherein the fatty acid salt comprises an ammonium salt of the fatty acid, a sodium salt of the fatty acid, a potassium salt of the fatty acid, a calcium salt of the fatty acid, a zinc salt of the fatty acid, a magnesium salt of the fatty acid, an iron salt of the fatty acid, a manganese salt of the fatty acid, an aluminum salt of the fatty acid, or any combination thereof.

9. The fibrous matrix of claim 6, wherein the fatty acid ester comprises stearyl acetate, stearyl citrate, stearyl palmitate, stearyl stearate, stearyl behenate, or any combination thereof.

10. The fibrous matrix of claim 6, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof comprises zinc stearate, magnesium stearate, aluminum stearate, stearic acid, or any combination thereof.

11. The fibrous substrate of claim 6, wherein the fatty acid amide comprises stearamide, ethylene bisstearamide, oleamide, ethylene bisoleamide, or any combination thereof.

12. The fibrous matrix of claim 6, wherein the fatty acid or its salt, ester, amide, derivative, or any combination thereof is present in a concentration of 0.1% to 50% by weight of the fibrous matrix.

13. The fibrous substrate of claim 1, wherein the acid is present.

14. The fibrous substrate of claim 12, wherein the acid is selected from the group consisting of hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, lactic acid, acetic acid, formic acid, malic acid, propionic acid, adipic acid, glycolic acid, citric acid, oxalic acid, uric acid, tartaric acid, and any combination thereof.

15. The fibrous substrate of claim 1, further comprising an internal sizing agent, a filler, or any combination thereof.

16. The fiber matrix of claim 15, wherein the internal sizing agent is an alkyl ketene dimer, an alkenyl ketene dimer, an aryl ketene dimer, an alkylaryl ketene dimer, alkenyl succinic anhydride, rosin, wax, stearic anhydride or other fatty acid anhydride.

17. The fibrous matrix of claim 1, wherein the pulping fibers comprise cellulosic fibers.

18. The fibrous matrix of claim 1, comprising pulping fibers, acetic acid, and a cationic polysaccharide distributed within the fibrous matrix.

19. The fibrous matrix of claim 1, comprising pulping fibers, acetic acid, zinc stearate, and a cationic polysaccharide distributed within the fibrous matrix.

20. The fibrous matrix of claim 1, wherein the pulping fibers comprise cellulosic fibers.

21. The fibrous matrix of claim 6, wherein the sum of the weight percent concentrations of all polysaccharides and all fatty acids or their salts, esters, amides, derivatives or any combination thereof present in the fibrous matrix is ​​greater than 5% to 55%.

22. A fibrous matrix comprising: Pulping fibers, and Fatty acids or their salts, esters, amides, derivatives or any combination thereof are distributed in the fiber matrix.

23. A method for preparing a fibrous matrix, the method comprising: blending pulping fibers, polysaccharide, and optionally fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

24. The method of claim 23, wherein the acid, when present, is present in the slurry at a concentration of 0.1% to 100% by weight of the polysaccharide.

25. A method for preparing a fibrous matrix according to claim 22, the method comprising: blending pulping fibers, fatty acids or their salts, esters, amides, derivatives, or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and The wet mat is compressed and heated to drive off the water, thereby forming the fibrous matrix.

26. An article comprising the fibrous matrix of claim 1.

27. The article of claim 26, wherein the article is oil and water resistant.

28. The method according to claim 26, wherein the article is Boxes, cups, clamshell boxes, plates, bowls, trays, cartons, envelopes, sacks, bags, pouches, pads, dividers, wrapping paper, film, sheet or cushioning material.

29. An article comprising the fibrous matrix of claim 13.

30. A method of making an article, the method comprising: blending pulping fibers, polysaccharide, and optionally fatty acid or its salt, ester, amide, derivative or any combination thereof, acid or any combination thereof, and water to produce a slurry; casting the slurry into a wet mat in the shape of a product; and The wet mat is compressed and heated to drive off the water, thereby forming the article.

Images